Method and System for Modeling a Process in a Process Plant

ABSTRACT

A system for detecting abnormal operation of at least a portion of a process plant includes a composite model for modeling at least the portion of the process plant. The model may be configurable to include multiple regression models corresponding to multiple different operating regions of the portion of the process plant. A new model may be generated from two or more of the regression models, and the composite model may be revised to replace the two or more regression models with the new model. The system may also include a deviation detector configured to determine if the actual operation of the portion of the process plant deviates significantly from the operation predicted by the composite model. If there is a significant deviation, this may indicate an abnormal operation.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is related to the following commonly-owned, co-pendingpatent application: U.S. patent application Ser. No. 11/492,467,entitled “METHOD AND SYSTEM FOR DETECTING ABNORMAL OPERATION IN APROCESS PLANT,” filed on Jul. 25, 2006. The above-referenced patentapplication is hereby incorporated by reference herein, in its entirety.

TECHNICAL FIELD

This disclosure relates generally to process control systems and, moreparticularly, to systems for monitoring and/or modeling processes.

DESCRIPTION OF THE RELATED ART

Process control systems, such as distributed or scalable process controlsystems like those used in chemical, petroleum or other processes,typically include one or more process controllers communicativelycoupled to each other, to at least one host or operator workstation andto one or more field devices via analog, digital or combinedanalog/digital buses. The field devices, which may be, for examplevalves, valve positioners, switches and transmitters (e.g., temperature,pressure and flow rate sensors), perform functions within the processsuch as opening or closing valves and measuring process parameters. Theprocess controller receives signals indicative of process measurementsmade by the field devices and/or other of information pertaining to thefield devices, uses this information to implement a control routine andthen generates control signals which are sent over the buses to thefield devices to control the operation of the process. Information fromthe field devices and the controller is typically made available to oneor more applications executed by the operator workstation to enable anoperator to perform any desired function with respect to the process,such as viewing the current state of the process, modifying theoperation of the process, etc.

In the past, conventional field devices were used to send and receiveanalog (e.g., 4 to 20 milliamps) signals to and from the processcontroller via an analog bus or analog lines. These 4 to 20 mA signalswere limited in nature in that they were indicative of measurements madeby the device or of control signals generated by the controller requiredto control the operation of the device. However, in the past decade orso, smart field devices including a microprocessor and a memory havebecome prevalent in the process control industry. In addition toperforming a primary function within the process, smart field devicesstore data pertaining to the device, communicate with the controllerand/or other devices in a digital or combined digital and analog format,and perform secondary tasks such as self calibration, identification,diagnostics, etc. A number of standard and open smart devicecommunication protocols such as the HART®, PROFIBUS®, WORLDFIP®, DeviceNet®, and CAN protocols, have been developed to enable smart fielddevices made by different manufacturers to be used together within thesame process control network. Moreover, the all digital, two wire busprotocol promulgated by the Fieldbus Foundation, known as theFOUNDATION™ Fieldbus (hereinafter “Fieldbus”) protocol uses functionblocks located in different field devices to perform control operationspreviously performed within a centralized controller. In this case, theFieldbus field devices are capable of storing and executing one or morefunction blocks, each of which receives inputs from and/or providesoutputs to other function blocks (either within the same device orwithin different devices), and performs some process control operation,such as measuring or detecting a process parameter, controlling a deviceor performing a control operation, like implementing aproportional-integral-derivative (PID) control routine. The differentfunction blocks within a process control system are configured tocommunicate with each other (e.g., over a bus) to form one or moreprocess control loops, the individual operations of which are spreadthroughout the process and are, thus, decentralized.

Information from the field devices and the process controllers istypically made available to one or more other hardware devices such asoperator workstations, maintenance workstations, personal computers,handheld devices, data historians, report generators, centralizeddatabases, etc., to enable an operator or a maintenance person toperform desired functions with respect to the process such as, forexample, changing settings of the process control routine, modifying theoperation of the control modules within the process controllers or thesmart field devices, viewing the current state of the process or ofparticular devices within the process plant, viewing alarms generated byfield devices and process controllers, simulating the operation of theprocess for the purpose of training personnel or testing the processcontrol software, diagnosing problems or hardware failures within theprocess plant, etc.

While a typical process plant has many process control andinstrumentation devices such as valves, transmitters, sensors, etc.connected to one or more process controllers, there are many othersupporting devices that are also necessary for or related to processoperation. These additional devices include, for example, power supplyequipment, power generation and distribution equipment, rotatingequipment such as turbines, motors, etc., which are located at numerousplaces in a typical plant. While this additional equipment does notnecessarily create or use process variables and, in many instances, isnot controlled or even coupled to a process controller for the purposeof affecting the process operation, this equipment is neverthelessimportant to, and ultimately necessary for proper operation of theprocess.

As is known, problems frequently arise within a process plantenvironment, especially a process plant having a large number of fielddevices and supporting equipment. These problems may take the form ofbroken or malfunctioning devices, logic elements, such as softwareroutines, being in improper modes, process control loops beingimproperly tuned, one or more failures in communications between deviceswithin the process plant, etc. These and other problems, while numerousin nature, generally result in the process operating in an abnormalstate (i.e., the process plant being in an abnormal situation) which isusually associated with suboptimal performance of the process plant.Many diagnostic tools and applications have been developed to detect anddetermine the cause of problems within a process plant and to assist anoperator or a maintenance person to diagnose and correct the problems,once the problems have occurred and been detected. For example, operatorworkstations, which are typically connected to the process controllersthrough communication connections such as a direct or wireless bus,Ethernet, modem, phone line, and the like, have processors and memoriesthat are adapted to run software or firmware, such as the DeltaV™ andOvation control systems, sold by Emerson Process Management whichincludes numerous control module and control loop diagnostic tools.Likewise, maintenance workstations, which may be connected to theprocess control devices, such as field devices, via the samecommunication connections as the controller applications, or viadifferent communication connections, such as OPC connections, handheldconnections, etc., typically include one or more applications designedto view maintenance alarms and alerts generated by field devices withinthe process plant, to test devices within the process plant and toperform maintenance activities on the field devices and other deviceswithin the process plant. Similar diagnostic applications have beendeveloped to diagnose problems within the supporting equipment withinthe process plant.

Thus, for example, the AMS™ Suite: Intelligent Device Managerapplication (at least partially disclosed in U.S. Pat. No. 5,960,214entitled “Integrated Communication Network for use in a Field DeviceManagement System”) sold by Emerson Process Management, enablescommunication with and stores data pertaining to field devices toascertain and track the operating state of the field devices. In someinstances, the AMS™ application may be used to communicate with a fielddevice to change parameters within the field device, to cause the fielddevice to run applications on itself such as, for example,self-calibration routines or self-diagnostic routines, to obtaininformation about the status or health of the field device, etc. Thisinformation may include, for example, status information (e.g., whetheran alarm or other similar event has occurred), device configurationinformation (e.g., the manner in which the field device is currently ormay be configured and the type of measuring units used by the fielddevice), device parameters (e.g., the field device range values andother parameters), etc. Of course, this information may be used by amaintenance person to monitor, maintain, and/or diagnose problems withfield devices.

Similarly, many process plants include equipment monitoring anddiagnostic applications such as, for example, Machinery Health™applications provided by CSI, or any other known applications used tomonitor, diagnose, and optimize the operating state of various rotatingequipment. Maintenance personnel usually use these applications tomaintain and oversee the performance of rotating equipment in the plant,to determine problems with the rotating equipment, and to determine whenand if the rotating equipment must be repaired or replaced. Similarly,many process plants include power control and diagnostic applicationssuch as those provided by, for example, the Liebert and ASCO companies,to control and maintain the power generation and distribution equipment.It is also known to run control optimization applications such as, forexample, real-time optimizers (RTO+), within a process plant to optimizethe control activities of the process plant. Such optimizationapplications typically use complex algorithms and/or models of theprocess plant to predict how inputs may be changed to optimize operationof the process plant with respect to some desired optimization variablesuch as, for example, profit.

These and other diagnostic and optimization applications are typicallyimplemented on a system-wide basis in one or more of the operator ormaintenance workstations, and may provide preconfigured displays to theoperator or maintenance personnel regarding the operating state of theprocess plant, or the devices and equipment within the process plant.Typical displays include alarming displays that receive alarms generatedby the process controllers or other devices within the process plant,control displays indicating the operating state of the processcontrollers and other devices within the process plant, maintenancedisplays indicating the operating state of the devices within theprocess plant, etc. Likewise, these and other diagnostic applicationsmay enable an operator or a maintenance person to retune a control loopor to reset other control parameters, to run a test on one or more fielddevices to determine the current status of those field devices, tocalibrate field devices or other equipment, or to perform other problemdetection and correction activities on devices and equipment within theprocess plant.

While these various applications and tools are very helpful inidentifying and correcting problems within a process plant, thesediagnostic applications are generally configured to be used only after aproblem has already occurred within a process plant and, therefore,after an abnormal situation already exists within the plant.Unfortunately, an abnormal situation may exist for some time before itis detected, identified and corrected using these tools, resulting inthe suboptimal performance of the process plant for the period of timeduring which the problem is detected, identified and corrected. In manycases, a control operator will first detect that some problem existsbased on alarms, alerts or poor performance of the process plant. Theoperator will then notify the maintenance personnel of the potentialproblem. The maintenance personnel may or may not detect an actualproblem and may need further prompting before actually running tests orother diagnostic applications, or performing other activities needed toidentify the actual problem. Once the problem is identified, themaintenance personnel may need to order parts and schedule a maintenanceprocedure, all of which may result in a significant period of timebetween the occurrence of a problem and the correction of that problem,during which time the process plant runs in an abnormal situationgenerally associated with the sub-optimal operation of the plant.

Additionally, many process plants can experience an abnormal situationwhich results in significant costs or damage within the plant in arelatively short amount of time. For example, some abnormal situationscan cause significant damage to equipment, the loss of raw materials, orsignificant unexpected downtime within the process plant if theseabnormal situations exist for even a short amount of time. Thus, merelydetecting a problem within the plant after the problem has occurred, nomatter how quickly the problem is corrected, may still result insignificant loss or damage within the process plant. As a result, it isdesirable to try to prevent abnormal situations from arising in thefirst place, instead of simply trying to react to and correct problemswithin the process plant after an abnormal situation arises.

One technique that may be used to collect data that enables a user topredict the occurrence of certain abnormal situations within a processplant before these abnormal situations actually arise, with the purposeof taking steps to prevent the predicted abnormal situation before anysignificant loss within the process plant takes place. This procedure isdisclosed in U.S. patent application Ser. No. 09/972,078, entitled “RootCause Diagnostics”, now U.S. Pat. No. 7,085,610 (based in part on U.S.patent application Ser. No. 08/623,569, now U.S. Pat. No. 6,017,143).The entire disclosures of both of these applications are herebyincorporated by reference herein. Generally speaking, this techniqueplaces statistical data collection and processing blocks or statisticalprocessing monitoring (SPM) blocks, in each of a number of devices, suchas field devices, within a process plant. The statistical datacollection and processing blocks collect, for example, process variabledata and determine certain statistical measures associated with thecollected data, such as a mean, a median, a standard deviation, etc.These statistical measures may then be sent to a user and analyzed torecognize patterns suggesting the future occurrence of a known abnormalsituation. Once a particular suspected future abnormal situation isdetected, steps may be taken to correct the underlying problem, therebyavoiding the abnormal situation in the first place.

Other techniques have been developed to monitor and detect problems in aprocess plant. One such technique is referred to as Statistical ProcessControl (SPC). SPC has been used to monitor variables, such as qualityvariables, associated with a process and flag an operator when thequality variable is detected to have moved from its “statistical” norm.With SPC, a small sample of a variable, such as a key quality variable,is used to generate statistical data for the small sample. Thestatistical data for the small sample is then compared to statisticaldata corresponding to a much larger sample of the variable. The variablemay be generated by a laboratory or analyzer, or retrieved from a datahistorian. SPC alarms are generated when the small sample's average orstandard deviation deviates from the large sample's average or standarddeviation, respectively, by some predetermined amount. An intent of SPCis to avoid making process adjustments based on normal statisticalvariation of the small samples. Charts of the average or standarddeviation of the small samples may be displayed to the operator on aconsole separate from a control console.

Another technique analyzes multiple variables and is referred to asmultivariable statistical process control (MSPC). This technique usesalgorithms such as principal component analysis (PCA) and projections tolatent structures (PLS) which analyze historical data to create astatistical model of the process. In particular, samples of variablescorresponding to normal operation and samples of variables correspondingto abnormal operation are analyzed to generate a model to determine whenan alarm should be generated. Once the model has been defined, variablescorresponding to a current process may be provided to the model, whichmay generate an alarm if the variables indicate an abnormal operation.

With model-based performance monitoring system techniques, a model isutilized, such as a correlation-based model or a first-principles model,that relates process inputs to process outputs. The model may becalibrated to the actual plant operation by adjusting internal tuningconstants or bias terms. The model can be used to predict when theprocess is moving into an abnormal region and alert the operator to takeaction. An alarm may be generated when there is a significant deviationin actual versus predicted behavior or when there is a big change in acalculated efficiency parameter. Model-based performance monitoringsystems typically cover as small as a single unit operation (e.g. apump, a compressor, a heater, a column, etc.) or a combination ofoperations that make up a process unit (e.g. crude unit, fluid catalyticcracking unit (FCCU), reformer, etc.)

SUMMARY OF THE DISCLOSURE

Example methods and systems are disclosed that may facilitate detectingan abnormal operation associated with a process plant. Generallyspeaking, a composite model for modeling at least a portion of theprocess plant may be configurable to include multiple regression modelscorresponding to multiple different operating regions of the portion ofthe process plant. Also, a new model may be generated from two or moreof the regression models, and the composite model may be revised toreplace the two or more regression models with the new model. Thecomposite model may be utilized, for example, by determining if theactual operation of the portion of the process plant deviatessignificantly from the operation predicted by the composite model. Ifthere is a significant deviation, this may indicate an abnormaloperation.

In one embodiment, a method for generating a model of a process in aprocess plant may comprise collecting a plurality of groups of data setsfor the process in the process plant, the data sets generated fromprocess variables of the process. The method may also comprisegenerating a plurality of regression models of the process using thegroups of data sets, wherein each regression model is generated using acorresponding group of data sets from the plurality of groups, andwherein each regression model comprises a plurality of correspondingparameters generated using the corresponding group of data sets.Additionally, the method may comprise generating a composite model ofthe process to include the plurality of regression models. Further, themethod may comprise generating a new model of the process usingparameters of at least two of the regression models, and revising thecomposite model of the process to replace the at least two of theregression models with the new model.

In another embodiment, a tangible medium storing machine readableinstructions is disclosed. The machine readable instructions may becapable of causing one or more machines to collect a plurality of groupsof data sets for the process in the process plant, the data setsgenerated from process variables of the process. Additionally, themachine readable instructions may be capable of causing one or moremachines to generate a plurality of regression models of the processusing the groups of data sets, wherein each regression model isgenerated using a corresponding group of data sets from the plurality ofgroups, and wherein each model comprises a plurality of correspondingparameters generated using the corresponding group of data sets. Also,the machine readable instructions may be capable of causing one or moremachines to generate a composite model of the process to include theplurality of regression models. Further, the machine readableinstructions may be capable of causing one or more machines to generatea new model of the process using parameters of at least two of theregression models, and to revise the composite model of the process toreplace the at least two of the regression models with the new model.

In yet another embodiment, a method for generating a model of a processin a process plant may comprise collecting data sets for the process inthe process plant, the data sets generated from process variables of theprocess, and generating a new regression model of the process using thecollected data sets. The method also may comprise revising a compositemodel of the process to include the new regression model in a pluralityof regression models of the composite model, wherein each regressionmodel in the plurality of regression models comprises a plurality ofcorresponding parameters generated using a corresponding group of datasets from a plurality of groups of data sets. Additionally, the methodmay comprise determining whether a number N of regression models in thecomposite model exceeds a number N_(MAX). The method may furthercomprise, if the number N of regression models exceeds the numberN_(MAX), generating a new model of the process using parameters of atleast two of the regression models in the plurality of regressionmodels, and revising the composite model of the process to replace theat least two of the regression models with the new model.

In still another embodiment, a tangible medium storing machine readableinstructions is disclosed. The machine readable instructions may becapable of causing one or more machines to collect data sets for theprocess in the process plant, the data sets generated from processvariables of the process. Additionally, the machine readableinstructions may be capable of causing one or more machines to generatea new regression model of the process using the collected data sets, andto revise a composite model of the process to include the new regressionmodel in a plurality of regression models of the composite model,wherein each regression model in the plurality of regression modelscomprises a plurality of corresponding parameters generated using acorresponding group of data sets from a plurality of groups of datasets. Further, the machine readable instructions may be capable ofcausing one or more machines to determine whether a number N ofregression models in the composite model exceeds a number N_(MAX), andto, if the number N of regression models exceeds the number N_(MAX),generate a new model of the process using parameters of at least two ofthe regression models in the plurality of regression models. Stillfurther, the machine readable instructions may be capable of causing oneor more machines to revise the composite model of the process to replacethe at least two of the regression models with the new model.

In yet another embodiment, a system for detecting an abnormal operationin a process plant may include a configurable composite model of theprocess in the process plant comprising a plurality of regressionmodels. Each regression model may have been generated using acorresponding group of data sets from a plurality of groups of datasets, the data sets generated from process variables of the process.Additionally, each regression model may comprise a plurality ofcorresponding parameters generated using the corresponding group of datasets. The configurable composite model may be capable of beingsubsequently configured to replace at least two of the regression modelswith a new model generated using parameters of the at least two of theregression models. The system may further include a deviation detectorcoupled to the configurable composite model, the deviation detectorconfigured to determine if the process significantly deviates from anoutput of the composite model.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exemplary block diagram of a process plant having adistributed control and maintenance network including one or moreoperator and maintenance workstations, controllers, field devices andsupporting equipment;

FIG. 2 is an exemplary block diagram of a portion of the process plantof FIG. 1, illustrating communication interconnections between variouscomponents of an abnormal situation prevention system located withindifferent elements of the process plant;

FIG. 3 is an example abnormal operation detection (AOD) system thatutilizes one or more regression models;

FIG. 4 is flow diagram of an example method that may be implementedusing the example AOD system of FIG. 3;

FIG. 5 is a flow diagram of an example method for initially training themodel of FIG. 3;

FIG. 6A is a graph showing a plurality of data sets that may be used bythe model of FIG. 3 to develop a regression model;

FIG. 6B is a graph showing a regression model developed using theplurality of data sets of FIG. 6A;

FIG. 6C is graph showing the regression model of FIG. 6B and its rangeof validity;

FIG. 7 is flow diagram of an example method that may be implementedusing the example abnormal operation detection system of FIG. 3;

FIG. 8A is a graph showing a received data set and a correspondingpredicted value generated by the model of FIG. 3;

FIG. 8B is a graph showing another received data set and anothercorresponding predicted value generated by the model of FIG. 3;

FIG. 9A is a graph showing a plurality of data sets that may be used bythe model of FIG. 3 to develop a second regression model in a differentoperating region;

FIG. 9B is a graph showing a second regression model developed using theplurality of data sets of FIG. 9A;

FIG. 9C is a graph showing an updated model and its range of validity;

FIG. 10 is a flow diagram of an example method for updating the model ofFIG. 3;

FIG. 11A is a graph showing a plurality of data sets that may be used bythe model of FIG. 3 to develop further regression models in differentoperating regions;

FIG. 11B is a graph showing a further regression models developed usingthe plurality of data sets of FIG. 11A;

FIG. 11C is a graph showing a further updated model and its range ofvalidity;

FIG. 12 is another example AOD system that utilizes one or moreregression models;

FIG. 13 is a block diagram of an example control system for regulatingthe level of material in a tank;

FIG. 14 is a block diagram of an example system that may be used todetect an abnormal condition associated with the control system of FIG.13;

FIG. 15 is an example state transition diagram corresponding to analternative operation of an AOD system such as the AOD systems of FIGS.3 and 12;

FIG. 16 is a flow diagram of an example method of operation in aLEARNING state of an AOD system;

FIG. 17 is a flow diagram of an example method for updating a model ofan AOD system;

FIG. 18 is a flow diagram of an example method of operation in aMONITORING state of an AOD system;

FIG. 19A is a graph showing a plurality of data sets collected during aLEARNING state an AOD system;

FIG. 19B is a graph showing an initial regression model corresponding tothe plurality of data sets of FIG. 19A;

FIG. 19C is a graph showing a received data set and a correspondingpredicted value generated during a MONITORING state of an AOD system;

FIG. 19D is a graph showing a received data set that is out of avalidity range of a model;

FIG. 19E is a graph showing a plurality of data sets in differentoperating region collected during a LEARNING state an AOD system;

FIG. 19F is a graph showing a second regression model developed usingthe plurality of data sets of FIG. 19E;

FIG. 19G is a graph showing an updated model and also showing a receiveddata set and a corresponding predicted value generated during aMONITORING state of an AOD system;

FIG. 19H is a graph showing a plurality of data sets collected during aLEARNING state an AOD system;

FIG. 19I is a graph showing an updated model developed using theplurality of data sets of FIG. 19H;

FIG. 20 is a block diagram of yet another example AOD system implementedon a Fieldbus segment of a process plant;

FIG. 21 is a depiction of an interface device connected within a furtherprocess plant to facilitate implementation of one or more AOD systems;

FIG. 22 is a depiction of an interface device connected within stillanother process plant to facilitate implementation of one or more AODsystems;

FIG. 23 is a graph illustrating the merger of two adjacent regressionmodels into a single regression model;

FIG. 24 is flow diagram of an example method for generating and revisinga composite model;

FIG. 25 is flow diagram of an example method for revising a compositemodel to replace two or more regression models with a new model;

FIG. 26A is a graph of an example composite model including fourregression models and three interpolation models;

FIG. 26B is a graph of the example composite model of FIG. 26A thatillustrates a new model calculated based on a first pair of regressionmodels;

FIG. 26C is a graph of the example composite model of FIG. 26A thatillustrates another new model calculated based on a second pair ofregression models;

FIG. 26D is a graph of the example composite model of FIG. 26A thatillustrates a further new model calculated based on a third pair ofregression models;

FIG. 26E is a graph of a revised composite model corresponding to theexample composite model of FIG. 26A wherein a pair of regression modelsand an interpolation model in FIG. 26A have been replaced by the newmodel illustrated in FIG. 26C; and

FIG. 27 is flow diagram of an example method for updating a compositemodel.

DETAILED DESCRIPTION

Referring now to FIG. 1, an example process plant 10 in which anabnormal situation prevention system may be implemented includes anumber of control and maintenance systems interconnected together withsupporting equipment via one or more communication networks. Inparticular, the process plant 10 of FIG. 1 includes one or more processcontrol systems 12 and 14. The process control system 12 may be atraditional process control system such as a PROVOX or RS3 system or anyother control system which includes an operator interface 12A coupled toa controller 12B and to input/output (I/O) cards 12C which, in turn, arecoupled to various field devices such as analog and Highway AddressableRemote Transmitter (HART) field devices 15. The process control system14, which may be a distributed process control system, includes one ormore operator interfaces 14A coupled to one or more distributedcontrollers 14B via a bus, such as an Ethernet bus. The controllers 14Bmay be, for example, DeltaV™ controllers sold by Emerson ProcessManagement of Austin, Tex. or any other desired type of controllers. Thecontrollers 14B are connected via I/O devices to one or more fielddevices 16, such as for example, HART or Fieldbus field devices or anyother smart or non-smart field devices including, for example, thosethat use any of the PROFIBUS®, WORLDFIP®, Device-Net®, AS-Interface andCAN protocols. As is known, the field devices 16 may provide analog ordigital information to the controllers 14B related to process variablesas well as to other device information. The operator interfaces 14A maystore and execute tools 17, 19 available to the process control operatorfor controlling the operation of the process including, for example,control optimizers, diagnostic experts, neural networks, tuners, etc.

Still further, maintenance systems, such as computers executing the AMS™Suite: Intelligent Device Manager application or any other devicemonitoring and communication applications may be connected to theprocess control systems 12 and 14 or to the individual devices thereinto perform maintenance and monitoring activities. For example, amaintenance computer 18 may be connected to the controller 12B and/or tothe devices 15 via any desired communication lines or networks(including wireless or handheld device networks) to communicate withand, in some instances, reconfigure or perform other maintenanceactivities on the devices 15. Similarly, maintenance applications suchas the AMS application may be installed in and executed by one or moreof the user interfaces 14A associated with the distributed processcontrol system 14 to perform maintenance and monitoring functions,including data collection related to the operating status of the devices16.

The process plant 10 also includes various rotating equipment 20, suchas turbines, motors, etc. which are connected to a maintenance computer22 via some permanent or temporary communication link (such as a bus, awireless communication system or hand held devices which are connectedto the equipment 20 to take readings and are then removed). Themaintenance computer 22 may store and execute known monitoring anddiagnostic applications 23 provided by, for example, CSI (an EmersonProcess Management Company) or other any other known applications usedto diagnose, monitor and optimize the operating state of the rotatingequipment 20. Maintenance personnel usually use the applications 23 tomaintain and oversee the performance of rotating equipment 20 in theplant 10, to determine problems with the rotating equipment 20 and todetermine when and if the rotating equipment 20 must be repaired orreplaced. In some cases, outside consultants or service organizationsmay temporarily acquire or measure data pertaining to the equipment 20and use this data to perform analyses for the equipment 20 to detectproblems, poor performance or other issues effecting the equipment 20.In these cases, the computers running the analyses may not be connectedto the rest of the system 10 via any communication line or may beconnected only temporarily.

Similarly, a power generation and distribution system 24 having powergenerating and distribution equipment 25 associated with the plant 10 isconnected via, for example, a bus, to another computer 26 which runs andoversees the operation of the power generating and distributionequipment 25 within the plant 10. The computer 26 may execute knownpower control and diagnostics applications 27 such a as those providedby, for example, Liebert and ASCO or other companies to control andmaintain the power generation and distribution equipment 25. Again, inmany cases, outside consultants or service organizations may use serviceapplications that temporarily acquire or measure data pertaining to theequipment 25 and use this data to perform analyses for the equipment 25to detect problems, poor performance or other issues effecting theequipment 25. In these cases, the computers (such as the computer 26)running the analyses may not be connected to the rest of the system 10via any communication line or may be connected only temporarily.

As illustrated in FIG. 1, a computer system 30 implements at least aportion of an abnormal situation prevention system 35, and inparticular, the computer system 30 stores and implements a configurationapplication 38 and, optionally, an abnormal operation detection system42, which will be described in more detail below. Additionally, thecomputer system 30 may implement an alert/alarm application 43.

Generally speaking, the abnormal situation prevention system 35 maycommunicate with abnormal operation detection systems (not shown inFIG. 1) optionally located in the field devices 15, 16, the controllers12B, 14B, the rotating equipment 20 or its supporting computer 22, thepower generation equipment 25 or its supporting computer 26, and anyother desired devices and equipment within the process plant 10, and/orthe abnormal operation detection system 42 in the computer system 30, toconfigure each of these abnormal operation detection systems and toreceive information regarding the operation of the devices or subsystemsthat they are monitoring. The abnormal situation prevention system 35may be communicatively connected via a hardwired bus 45 to each of atleast some of the computers or devices within the plant 10 or,alternatively, may be connected via any other desired communicationconnection including, for example, wireless connections, dedicatedconnections which use OPC, intermittent connections, such as ones whichrely on handheld devices to collect data, etc. Likewise, the abnormalsituation prevention system 35 may obtain data pertaining to the fielddevices and equipment within the process plant 10 via a LAN or a publicconnection, such as the Internet, a telephone connection, etc.(illustrated in FIG. 1 as an Internet connection 46) with such databeing collected by, for example, a third party service provider.Further, the abnormal situation prevention system 35 may becommunicatively coupled to computers/devices in the plant 10 via avariety of techniques and/or protocols including, for example, Ethernet,Modbus, HTML, XML, proprietary techniques/protocols, etc. Thus, althoughparticular examples using OPC to communicatively couple the abnormalsituation prevention system 35 to computers/devices in the plant 10 aredescribed herein, one of ordinary skill in the art will recognize that avariety of other methods of coupling the abnormal situation preventionsystem 35 to computers/devices in the plant 10 can be used as well.

FIG. 2 illustrates a portion 50 of the example process plant 10 of FIG.1 for the purpose of describing one manner in which the abnormalsituation prevention system 35 and/or the alert/alarm application 43 maycommunicate with various devices in the portion 50 of the exampleprocess plant 10. While FIG. 2 illustrates communications between theabnormal situation prevention system 35 and one or more abnormaloperation detection systems within HART and Fieldbus field devices, itwill be understood that similar communications can occur between theabnormal situation prevention system 35 and other devices and equipmentwithin the process plant 10, including any of the devices and equipmentillustrated in FIG. 1.

The portion 50 of the process plant 10 illustrated in FIG. 2 includes adistributed process control system 54 having one or more processcontrollers 60 connected to one or more field devices 64 and 66 viainput/output (I/O) cards or devices 68 and 70, which may be any desiredtypes of I/O devices conforming to any desired communication orcontroller protocol. The field devices 64 are illustrated as HART fielddevices and the field devices 66 are illustrated as Fieldbus fielddevices, although these field devices could use any other desiredcommunication protocols. Additionally, each of the field devices 64 and66 may be any type of device such as, for example, a sensor, a valve, atransmitter, a positioner, etc., and may conform to any desired open,proprietary or other communication or programming protocol, it beingunderstood that the I/O devices 68 and 70 must be compatible with thedesired protocol used by the field devices 64 and 66.

In any event, one or more user interfaces or computers 72 and 74 (whichmay be any types of personal computers, workstations, etc.) accessibleby plant personnel such as configuration engineers, process controloperators, maintenance personnel, plant managers, supervisors, etc. arecoupled to the process controllers 60 via a communication line or bus 76which may be implemented using any desired hardwired or wirelesscommunication structure, and using any desired or suitable communicationprotocol such as, for example, an Ethernet protocol. In addition, adatabase 78 may be connected to the communication bus 76 to operate as adata historian that collects and stores configuration information aswell as on-line process variable data, parameter data, status data, andother data associated with the process controllers 60 and field devices64 and 66 within the process plant 10. Thus, the database 78 may operateas a configuration database to store the current configuration,including process configuration modules, as well as controlconfiguration information for the process control system 54 asdownloaded to and stored within the process controllers 60 and the fielddevices 64 and 66. Likewise, the database 78 may store historicalabnormal situation prevention data, including statistical data collectedby the field devices 64 and 66 within the process plant 10, statisticaldata determined from process variables collected by the field devices 64and 66, and other types of data that will be described below.

While the process controllers 60, I/O devices 68 and 70, and fielddevices 64 and 66 are typically located down within and distributedthroughout the sometimes harsh plant environment, the workstations 72and 74, and the database 78 are usually located in control rooms,maintenance rooms or other less harsh environments easily accessible byoperators, maintenance personnel, etc.

Generally speaking, the process controllers 60 store and execute one ormore controller applications that implement control strategies using anumber of different, independently executed, control modules or blocks.The control modules may each be made up of what are commonly referred toas function blocks, wherein each function block is a part or asubroutine of an overall control routine and operates in conjunctionwith other function blocks (via communications called links) toimplement process control loops within the process plant 10. As is wellknown, function blocks, which may be objects in an object-orientedprogramming protocol, typically perform one of an input function, suchas that associated with a transmitter, a sensor or other processparameter measurement device, a control function, such as thatassociated with a control routine that performs PID, fuzzy logic, etc.control, or an output function, which controls the operation of somedevice, such as a valve, to perform some physical function within theprocess plant 10. Of course, hybrid and other types of complex functionblocks exist, such as model predictive controllers (MPCs), optimizers,etc. It is to be understood that while the Fieldbus protocol and theDeltaV™ system protocol use control modules and function blocks designedand implemented in an object-oriented programming protocol, the controlmodules may be designed using any desired control programming schemeincluding, for example, sequential function blocks, ladder logic, etc.,and are not limited to being designed using function blocks or any otherparticular programming technique.

As illustrated in FIG. 2, the maintenance workstation 74 includes aprocessor 74A, a memory 74B and a display device 74C. The memory 74Bstores the abnormal situation prevention application 35 and thealert/alarm application 43 discussed with respect to FIG. 1 in a mannerthat these applications can be implemented on the processor 74A toprovide information to a user via the display 74C (or any other displaydevice, such as a printer).

Each of one or more of the field devices 64 and 66 may include a memory(not shown) for storing routines such as routines for implementingstatistical data collection pertaining to one or more process variablessensed by sensing device and/or routines for abnormal operationdetection, which will be described below. Each of one or more of thefield devices 64 and 66 may also include a processor (not shown) thatexecutes routines such as routines for implementing statistical datacollection and/or routines for abnormal operation detection. Statisticaldata collection and/or abnormal operation detection need not beimplemented by software. Rather, one of ordinary skill in the art willrecognize that such systems may be implemented by any combination ofsoftware, firmware, and/or hardware within one or more field devicesand/or other devices.

As shown in FIG. 2, some (and potentially all) of the field devices 64and 66 include abnormal operation detection blocks 80 and 82, which willbe described in more detail below. While the blocks 80 and 82 of FIG. 2are illustrated as being located in one of the devices 64 and in one ofthe devices 66, these or similar blocks could be located in any numberof the field devices 64 and 66, could be located in other devices, suchas the controller 60, the I/O devices 68, 70 or any of the devicesillustrated in FIG. 1. Additionally, the blocks 80 and 82 could be inany subset of the devices 64 and 66.

Generally speaking, the blocks 80 and 82 or sub-elements of theseblocks, collect data, such a process variable data, from the device inwhich they are located and/or from other devices. Additionally, theblocks 80 and 82 or sub-elements of these blocks may process thevariable data and perform an analysis on the data for any number ofreasons. For example, the block 80, which is illustrated as beingassociated with a valve, may have a stuck valve detection routine whichanalyzes the valve process variable data to determine if the valve is ina stuck condition. In addition, the block 80 may include a set of one ormore statistical process monitoring (SPM) blocks or units such as blocksSPM1-SPM4 which may collect process variable or other data within thevalve and perform one or more statistical calculations on the collecteddata to determine, for example, a mean, a median, a standard deviation,a root-mean-square (RMS), a rate of change, a range, a minimum, amaximum, etc. of the collected data and/or to detect events such asdrift, bias, noise, spikes, etc., in the collected data. The specificstatistical data generated, nor the method in which it is generated isnot critical. Thus, different types of statistical data can be generatedin addition to, or instead of, the specific types described above.Additionally, a variety of techniques, including known techniques, canbe used to generate such data. The term statistical process monitoring(SPM) block is used herein to describe functionality that performsstatistical process monitoring on at least one process variable or otherprocess parameter, and may be performed by any desired software,firmware or hardware within the device or even outside of a device forwhich data is collected. It will be understood that, because the SPMsare generally located in the devices where the device data is collected,the SPMs can acquire quantitatively more and qualitatively more accurateprocess variable data. As a result, the SPM blocks are generally capableof determining better statistical calculations with respect to thecollected process variable data than a block located outside of thedevice in which the process variable data is collected.

It is to be understood that although the blocks 80 and 82 are shown toinclude SPM blocks in FIG. 2, the SPM blocks may instead be stand-aloneblocks separate from the blocks 80 and 82, and may be located in thesame device as the corresponding block 80 or 82 or may be in a differentdevice. The SPM blocks discussed herein may comprise known FoundationFieldbus SPM blocks, or SPM blocks that have different or additionalcapabilities as compared with known Foundation Fieldbus SPM blocks. Theterm statistical process monitoring (SPM) block is used herein to referto any type of block or element that collects data, such as processvariable data, and performs some statistical processing on this data todetermine a statistical measure, such as a mean, a standard deviation,etc. As a result, this term is intended to cover software, firmware,hardware and/or other elements that perform this function, whether theseelements are in the form of function blocks, or other types of blocks,programs, routines or elements and whether or not these elements conformto the Foundation Fieldbus protocol, or some other protocol, such asProfibus, HART, CAN, etc. protocol. If desired, the underlying operationof blocks 50 may be performed or implemented at least partially asdescribed in U.S. Pat. No. 6,017,143, which is hereby incorporated byreference herein.

It is to be understood that although the blocks 80 and 82 are shown toinclude SPM blocks in FIG. 2, SPM blocks are not required of the blocks80 and 82. For example, abnormal operation detection routines of theblocks 80 and 82 could operate using process variable data not processedby an SPM block. As another example, the blocks 80 and 82 could eachreceive and operate on data provided by one or more SPM block located inother devices. As yet another example, the process variable data couldbe processed in a manner that is not provided by many typical SPMblocks. As just one example, the process variable data could be filteredby a finite impulse response (FIR) or infinite impulse response (IIR)filter such as a bandpass filter or some other type of filter. Asanother example, the process variable data could be trimmed so that itremained in a particular range. Of course, known SPM blocks could bemodified to provide such different or additional processingcapabilities.

The block 82 of FIG. 2, which is illustrated as being associated with atransmitter, may have a plugged line detection unit that analyzes theprocess variable data collected by the transmitter to determine if aline within the plant is plugged. In addition, the block 82 may includesone or more SPM blocks or units such as blocks SPM1-SPM4 which maycollect process variable or other data within the transmitter andperform one or more statistical calculations on the collected data todetermine, for example, a mean, a median, a standard deviation, etc. ofthe collected data. While the blocks 80 and 82 are illustrated asincluding four SPM blocks each, the blocks 80 and 82 could have anyother number of SPM blocks therein for collecting and determiningstatistical data.

Overview of an Abnormal Operation Detection (AOD) System

FIG. 3 is a block diagram of an example abnormal operation detection(AOD) system 100 that could be utilized in the abnormal operationdetection blocks 80 and 82 of FIG. 2. The AOD system 100 includes afirst SPM block 104 and a second SPM block 108 coupled to a model 112.The first SPM block 104 receives a first process variable and generatesfirst statistical data from the first process variable. The firststatistical data could be any of various kinds of statistical data suchas mean data, median data, standard deviation data, rate of change data,range data, etc., calculated from the first process variable. Such datacould be calculated based on a sliding window of first process variabledata or based on non-overlapping windows of first process variable data.As one example, the first SPM block 104 may generate mean data using amost recent first process variable sample and 49 previous samples of thefirst process variable. In this example, a mean variable value may begenerated for each new first process variable sample received by thefirst SPM block 104. As another example, the first SPM block 104 maygenerate mean data using non-overlapping time periods. In this example,a window of five minutes (or some other suitable time period) could beused, and a mean variable value would thus be generated every fiveminutes. In a similar manner, the second SPM block 108 receives a secondprocess variable and generates second statistical data from the secondprocess variable in a manner similar to the SPM block 104.

The model 112 includes an independent variable X input and a dependentvariable Y. As will be described in more detail below, the model 112 maybe trained using a plurality of data sets (X, Y), to model Y (dependentvariable) as a function of X (independent variable). As will bedescribed in more detail below, the model 112 may include one or moreregression models, each regression model for a different operatingregion. Each regression model may utilize a function to model thedependent variable Y as a function of the independent variable X oversome range of X. The regression model may comprise be a linearregression model, for example, or some other regression model.Generally, a linear regression model comprises some linear combinationof functions f(X), g(X), h(X), . . . . For modeling an industrialprocess, a typically adequate linear regression model may comprise afirst order function of X (e.g., Y=m*X+b) or a second order function ofX (e.g., Y=a*X²+b*X+c). Of course, other types of functions may beutilized as well such as higher order polynomials, sinusoidal functions,logarithmic functions, exponential functions, power functions, etc.

After it has been trained, the model 112 may be used to generate apredicted value (Y_(P)) of a dependent variable Y based on a givenindependent variable X input. The output Y_(P) of the model 112 isprovided to a deviation detector 116. The deviation detector 116receives the output Y_(P) of the regression model 112 as well as thedependent variable input Y to the model 112. Generally speaking, thedeviation detector 116 compares the dependent variable Y to the valueY_(P) generated by the model 112 to determine if the dependent variableY is significantly deviating from the predicted value Y_(P). If thedependent variable Y is significantly deviating from the predicted valueY_(P), this may indicate that an abnormal situation has occurred, isoccurring, or may occur in the near future, and thus the deviationdetector 116 may generate an indicator of the deviation. In someimplementations, the indicator may comprise an alert or alarm.

One of ordinary skill in the art will recognize that the AOD system 100can be modified in various ways. For example, the SPM blocks 104 and 108could be omitted. As another example, other types of processing inaddition to or instead of the SPM blocks 104 and 108 could be utilized.For example, the process variable data could be filtered, trimmed, etc.,prior to the SPM blocks 104 and 108, or rather than utilizing the SPMblocks 104 and 108.

Additionally, although the model 112 is illustrated as having a singleindependent variable input X, a single dependent variable input Y, and asingle predicted value Y_(P), the model 112 could include a regressionmodel that models multiple variables Y as a function of multiplevariables X. For example, the model 112 could comprise a multiple linearregression (MLR) model, a principal component regression (PCR) model, apartial least squares (PLS) model, a ridge regression (RR) model, avariable subset selection (VSS) model, a support vector machine (SVM)model, etc.

The AOD system 100 could be implemented wholly or partially in a fielddevice. As just one example, the SPM blocks 104 and 108 could beimplemented in a field device 66 and the model 112 and/or the deviationdetector 116 could be implemented in the controller 60 or some otherdevice. In one particular implementation, the AOD system 100 could beimplemented as a function block, such as a function block to be used insystem that implements a Fieldbus protocol. Such a function block may ormay not include the SPM blocks 104 and 108. In another implementation,each of at least some of the blocks 104, 108, 112, and 116 may beimplemented as a function block.

The AOD system 100 may be in communication with the abnormal situationprevention system 35 (FIGS. 1 and 2). For example, the AOD system 100may be in communication with the configuration application 38 to permita user to configure the AOD system 100. For instance, one or more of theSPM blocks 104 and 108, the model 112, and the deviation detector 116may have user configurable parameters that may be modified via theconfiguration application 38.

Additionally, the AOD system 100 may provide information to the abnormalsituation prevention system 35 and/or other systems in the processplant. For example, the deviation indicator generated by the deviationdetector 116 could be provided to the abnormal situation preventionsystem 35 and/or the alert/alarm application 43 to notify an operator ofthe abnormal condition. As another example, after the model 112 has beentrained, parameters of the model could be provided to the abnormalsituation prevention system 35 and/or other systems in the process plantso that an operator can examine the model and/or so that the modelparameters can be stored in a database. As yet another example, the AODsystem 100 may provide X, Y, and/or Y_(P) values to the abnormalsituation prevention system 35 so that an operator can view the values,for instance, when a deviation has been detected.

FIG. 4 is a flow diagram of an example method 150 for detecting anabnormal operation in a process plant. The method 150 could beimplemented using the example AOD system 100 of FIG. 3 and will be usedto explain the operation of the AOD system 100. However, one of ordinaryskill in the art will recognize that the method 150 could be implementedby a system different than the AOD system 100. At a block 154, a model,such as the model 112, is trained. For example, the model could betrained using independent variable X and dependent variable Y data setsto configure it to model Y as a function of X. The model could includemultiple regression models that each model Y as a function of X for adifferent range of X.

Then, at a block 158, the trained model generates predicted values(Y_(P)) of the dependent variable Y using values of the independentvariable X that it receives. Next, at a block 162, the actual values ofY are compared to the corresponding predicted values Y_(P) to determineif Y is significantly deviating from Y_(P). For example, the deviationdetector 116 receives the output Y_(P) of the model 112 and compares itto the dependent variable Y. If it is determined that Y hassignificantly deviated from Y_(P) an indicator of the deviation may begenerated at a block 166. In the AOD system 100, for example, thedeviation detector 116 may generate the indicator. The indicator may bean alert or alarm, for example, or any other type of signal, flag,message, etc., indicating that a significant deviation has beendetected.

As will be discussed in more detail below, the block 154 may be repeatedafter the model has been initially trained and after it has generatedpredicted values Y_(P) of the dependent variable Y. For example, themodel could be retrained if a set point in the process has been changed.

Overview of the Model

FIG. 5 is a flow diagram of an example method 200 for initially traininga model such as the model 112 of FIG. 3. At a block 204, at least anadequate number of data sets (X, Y) for the independent variable X andthe dependent variable Y may be received in order to train a model. Asdescribed above, the data sets (X, Y) may comprise process variabledata, process variable data that has been filtered or otherwiseprocessed, statistical data generated from the process variable data,etc. In the AOD system of FIG. 3, the model 112 may receive data sets(X, Y) from the SPM blocks 104 and 108. Referring now to FIG. 6A, agraph 220 shows an example of a plurality of data sets (X,Y) received bya model.

Referring again to FIG. 5, at a block 208, a validity range [X_(MIN),X_(MAX)] for the model may be generated. The validity range may indicatea range of the independent variable X for which the model is valid. Forinstance, the validity range may indicate that the model is valid onlyfor X values in which X is greater than or equal to X_(MIN) and lessthan or equal to X_(MAX). As just one example, X_(MIN) could be set asthe smallest value of X in the data sets (X,Y) received at the block204, and X_(MAX) could be set as the largest value of X in the data sets(X,Y) received at the block 204. Referring again to FIG. 6A, X_(MIN)could be set to the X value of the leftmost data set, and X_(MAX) couldbe set as the X value of the rightmost data set, for example. Of course,the determination of validity range could be implemented in other waysas well. In the AOD system 100 of FIG. 3, the model block 112 couldgenerate the validity range.

At a block 212, a regression model for the range [X_(MIN), X_(MAX)] maybe generated based on the data sets (X, Y) received at the block 204.Any of a variety of techniques, including known techniques, may be usedto generate the regression model, and any of a variety of functionscould be used as the model. For example, the model of could comprise alinear equation, a quadratic equation, a higher order equation, etc. InFIG. 6B, a curve 224 superimposed on the data sets (X, Y) received atthe block 204 illustrates a regression model that has been generated tomodel the data sets (X, Y). In FIG. 6C, the curve 224 is illustratedwithout the data sets (X, Y). The regression model corresponding to thecurve 224 is valid in the range [X_(MIN), X_(MAX)]. In the AOD system100 of FIG. 3, the model block 112 could generate the regression modelfor the range [X_(MIN), X_(MAX)].

Utilizing the Model Through Operating Region Changes

It may be that, after the model has been initially trained, the systemthat it models may move into a different, but normal operating region.For example, a set point may be changed. FIG. 7 is a flow diagram of anexample method 240 for using a model to determine whether abnormaloperation is occurring, has occurred, or may occur, wherein the modelmay be updated if the modeled process moves into a different operatingregion. The method 240 may be implemented by an AOD system such as theAOD system 100 of FIG. 3. Of course, the method 240 could be implementedby other types of AOD systems as well. The method 240 may be implementedafter an initial model has been generated. The method 200 of FIG. 5, forexample, could be used to generate the initial model.

At a block 244, a data set (X, Y) is received. In the AOD system 100 ofFIG. 3, the model 112 could receive a data set (X, Y) from the SPMblocks 104 and 108, for example. Then, at a block 248, it may bedetermined whether the data set (X, Y) received at the block 244 is in avalidity range. The validity range may indicate a range in which themodel is valid. In the AOD system 100 of FIG. 3, the model 112 couldexamine the value X received at the block 244 to determine if it iswithin the validity range [X_(MIN), X_(MAX)]. If it is determined thatthe data set (X, Y) received at the block 244 is in the validity range,the flow may proceed to a block 252.

At the block 252, a predicted value Y_(P) of the dependent variable Ymay be generated using the model. In particular, the model generates thepredicted value Y_(P) from the value X received at the block 244. In theAOD system 100 of FIG. 3, the model 112 generates the predicted valueY_(P) from the value X received from the SPM block 104.

Then, at a block 256, the value Y received at the block 244 may becompared with the predicted value Y_(P). The comparison may beimplemented in a variety of ways. For example, a difference or apercentage difference could be generated. Other types of comparisonscould be used as well. Referring now to FIG. 8A, an example receiveddata set is illustrated in the graph 220 as a dot, and the correspondingpredicted value, Y_(P), is illustrated as an “x”. As illustrated in FIG.8A, it has been calculated that the difference between Y received at theblock 244 and the predicted value Y_(P) is −1.9808%. Referring now toFIG. 8B, another example received data set is illustrated in the graph220 as a dot, and the corresponding predicted value, Y_(P), isillustrated as an “x”. As illustrated in FIG. 8B, it has been calculatedthat the difference between Y received at the block 244 and thepredicted value Y_(P) is −28.957%. In the AOD system 100 of FIG. 3, thedeviation detector 116 may perform the comparison.

Referring again to FIG. 7, at a block 260, it may be determined whetherthe value Y received at the block 244 significantly deviates from thepredicted value Y_(P) based on the comparison of the block 256. Thedetermination at the block 260 may be implemented in a variety of waysand may depend upon how the comparison of the block 256 was implemented.For example, if a difference value was generated at the block 256, itmay be determined whether this difference value exceeds some threshold.The threshold may be a predetermined or configurable value. Also, thethreshold may be constant or may vary. For example, the threshold mayvary depending upon the value of the independent variable X valuereceived at the block 244. As another example, if a percentagedifference value was generated at the block 256, it may be determinedwhether this percentage value exceeds some threshold percentage. As yetanother example, a significant deviation may be determined only if twoor some other number of consecutive comparisons exceed a threshold.Referring again to FIG. 8A, the difference between Y received at theblock 244 and the predicted value Y_(P) is −1.9808%. If, for example, athreshold of 10% is to be used to determine whether a deviation issignificant, the absolute value of the difference illustrated in FIG. 8Ais below that threshold Referring again to FIG. 8B on the other hand,the difference between Y received at the block 244 and the predictedvalue Y_(P) is −28.957%. The absolute value of the differenceillustrated in FIG. 8B is above the threshold value 10% so an abnormalcondition indicator may be generated as will be discussed below. In theAOD system 100 of FIG. 3, the deviation detector 116 may implement theblock 260.

In general, determining if the value Y significantly deviates from thepredicted value Y_(P) may be implemented using a variety of techniques,including known techniques. For instance, determining if the value Ysignificantly deviates from the predicted value Y_(P) may includeanalyzing the present values of Y and Y_(P). For example, Y could besubtracted from Y_(P), or vice versa, and the result may be compared toa threshold to see if it exceeds the threshold. It may optionallycomprise also analyzing past values of Y and Y_(P). Further, it maycomprise comparing Y or a difference between Y and Y_(P) to one or morethresholds. Each of the one or more thresholds may be fixed or maychange. For example, a threshold may change depending on the value of Xor some other variable. U.S. patent application Ser. No. 11/492,347,entitled “METHODS AND SYSTEMS FOR DETECTING DEVIATION OF A PROCESSVARIABLE FROM EXPECTED VALUES,” filed Jul. 25, 2006, and which is herebyincorporated by reference herein, describes example systems and methodsfor detecting whether a process variable significantly deviates from anexpected value, and any of these systems and methods may optionally beutilized. One of ordinary skill in the art will recognize many otherways of determining if the value Y significantly deviates from thepredicted value Y_(P). Further, blocks 256 and 260 may be combined.

Some or all of criteria to be used in the comparing Y to Y_(P)(block256) and/or the criteria to be used in determining if Y significantlydeviates from Y_(P)(block 260) may be configurable by a user via theconfiguration application 38 (FIGS. 1 and 2) for example. For instance,the type of comparison (e.g., generate difference, generate absolutevalue of difference, generate percentage difference, etc.) may beconfigurable. Also, the threshold or thresholds to be used indetermining whether the deviation is significant may be configurable.Alternatively, such criteria may not be readily configurable by anoperator.

Referring again to FIG. 7, if it is determined that the value Y receivedat the block 244 does not significantly deviate from the predicted valueY_(P), the flow may return to the block 244 to receive the next data set(X,Y). If however, it is determined that the value Y does significantlydeviate from the predicted value Y_(P), the flow may proceed to theblock 264. At the block 264, an indicator of a deviation may begenerated. The indicator may be an alert or alarm, for example. Thegenerated indicator may include additional information such as whetherthe value Y received at the block 244 was higher than expected or lowerthan expected, for example. Referring to FIG. 8A, because the differencebetween Y received at the block 244 and the predicted value Y_(P) is−1.9808%, which is below the threshold 10%, no indicator is generated.On the other hand, referring to FIG. 8B, the difference between Yreceived at the block 244 and the predicted value Y_(P) is −28.957%,which is above the threshold 10%. Therefore, an indicator is generated.In the AOD system 100 of FIG. 3, the deviation detector 116 may generatethe indicator.

Referring again to the block 248 of FIG. 7, if it is determined that thedata set (X, Y) received at the block 244 is not in the validity range,the flow may proceed to a block 268. Referring now to FIG. 9A, it showsa graph illustrating a received data set 290 that is not in the validityrange. Referring again to FIG. 7, at the block 268, the data set (X, Y)received at the block 244 may be added to an appropriate group of datasets that may be used to train the model at a subsequent time. Forexample, if the value of X received at the block 244 is less thanX_(MIN), the data set (X,Y) received at the block 244 may be added to adata group corresponding to other received data sets in which the valueof X is less than X_(MIN). Similarly, if the value of X received at theblock 244 is greater than X_(MAX), the data set (X,Y) received at theblock 244 may be added to a data group corresponding to other receiveddata sets in which the value of X is greater than X_(MAX). Referring toFIG. 9A, the data set 290 has been added to a group of data sets 294corresponding to data sets in which the value of X is less than X_(MIN).In the AOD system 100 of FIG. 3, the model block 112 may implement theblock 268.

Then, at a block 272, it may be determined if enough data sets are inthe data group to which the data set was added at the block 268 in orderto generate a regression model corresponding to the data in that group.This determination may be implemented using a variety of techniques. Forexample, the number of data sets in the group may be compared to aminimum number, and if the number of data sets in the group is at leastthis minimum number, it may be determined that there are enough datasets in order to generate a regression model. The minimum number may beselected using a variety of techniques, including techniques known tothose of ordinary skill in the art. If it is determined that there areenough data sets in order to generate a regression model, the model maybe updated at a block 276, as will be described below with reference toFIG. 10. If it is determined, however, that there are not enough datasets in order to generate a regression model, the flow may return to theblock 244 to receive the next data set (X, Y).

FIG. 10 is a flow diagram of an example method 276 for updating themodel after it is determined that there are enough data sets in a groupin order to generate a regression model for data sets outside thecurrent validity range [X_(MIN), X_(MAX)]. At a block 304, a range[X′_(MIN), X′_(MAX)] for a new regression model may be determined. Thevalidity range may indicate a range of the independent variable X forwhich the new regression model will be valid. For instance, the validityrange may indicate that the model is valid only for X values in which Xis greater than or equal to X′_(MIN) and less than or equal to X′_(MAX).As just one example, X′_(MIN) could be set as the smallest value of X inthe group of data sets (X,Y), and X′_(MAX) could be set as the largestvalue of X in the group of data sets (X,Y). Referring again to FIG. 9A,X′_(MIN) could be set to the X value of the leftmost data set in thegroup 294, and X′_(MAX) could be set as the X value of the rightmostdata set in the group 294, for example. In the AOD system 100 of FIG. 3,the model block 112 could generate the validity range.

At a block 308, a regression model for the range [X′_(MIN), X′_(MAX)]may be generated based on the data sets (X, Y) in the group. Any of avariety of techniques, including known techniques, may be used togenerate the regression model, and any of a variety of functions couldbe used as the model. For example, the model could comprise a linearequation, a quadratic equation, etc. In FIG. 9B, a curve 312superimposed on the group 294 illustrates a regression model that hasbeen generated to model the data sets in the group 294. The regressionmodel corresponding to the curve 312 is valid in the range [X′_(MIN),X′_(MAX)], and the regression model corresponding to the curve 224 isvalid in the range [X_(MIN), X_(MAX)]. In the AOD system 100 of FIG. 3,the model 112 could generate the regression model for the range[X′_(MIN), X′_(MAX)].

For ease of explanation, the range [X_(MIN), X_(MAX)] will now bereferred to as [X_(MIN) _(—) ₁, X_(MAX) _(—) ₁], and the range[X′_(MIN), X′_(MAX)] will now be referred to as [X_(MIN) _(—) ₂, X_(MAX)_(—) ₂]. Additionally, the regression model corresponding to the range[X_(MIN) _(—) ₁, X_(MAX) _(—) ₁] will be referred to as f₁(x), andregression model corresponding to the range [X_(MIN) _(—) ₂, X_(MAX)_(—) ₂] will be referred to as f₂(x). Thus, the model may now berepresented as:

$\begin{matrix}{{f(X)} = \{ \begin{matrix}{{{f_{1}(X)}\mspace{14mu} {for}\mspace{14mu} X_{{MIN\_}1}} \leq X \leq X_{{MAX\_}1}} \\{{{f_{2}(X)}\mspace{14mu} {for}\mspace{14mu} X_{{MIN\_}2}} \leq X \leq X_{{MAX\_}2}}\end{matrix} } & ( {{Equ}.\mspace{14mu} 1} )\end{matrix}$

Referring again to FIG. 10, at a block 316, an interpolation model maybe generated between the regression models corresponding to the ranges[X_(MIN) _(—) ₁, X_(MAX) _(—) ₁] and [X_(MIN) _(—) ₂, X_(MAX) _(—) ₂].The interpolation model described below comprises a linear function, butin other implementations, other types of functions, such as a quadraticfunction, can be used. If X_(MAX) _(—) ₁ is less than X_(MIN) _(—) ₂,then the interpolation model may be calculated as:

$\begin{matrix}{{( \frac{{f_{2}( X_{{MIN\_}2} )} - {f_{1}( X_{{MAX\_}1} )}}{X_{{MIN\_}2} - X_{{MAX\_}1}} )( {X - X_{{MIN\_}2}} )} + {f_{2}( X_{{MIN\_}2} )}} & ( {{Equ}.\mspace{14mu} 2} )\end{matrix}$

Similarly, if X_(MAX) _(—) ₂ is less than X_(MIN) _(—) ₁, then theinterpolation model may be calculated as:

$\begin{matrix}{{( \frac{{f_{1}( X_{{MIN\_}1} )} - {f_{2}( X_{{MAX\_}2} )}}{X_{{MIN\_}1} - X_{{MAX\_}2}} )( {X - X_{{MIN\_}1}} )} + {f_{1}( X_{{MIN\_}1} )}} & ( {{Equ}.\mspace{14mu} 3} )\end{matrix}$

Thus, the model may now be represented as:

$\begin{matrix}{{f(X)} = \{ \begin{matrix}{{f_{1}(X)}} & {{{for}\mspace{14mu} X_{{MIN\_}1}} \leq X \leq X_{{MAX\_}1}} \\{{{( \frac{{f_{2}( X_{{MIN\_}2} )} - {f_{1}( X_{{MAX\_}1} )}}{X_{{MIN\_}2} - X_{{MAX\_}1}} )( {X - X_{{MIN\_}2}} )} + {f_{2}( X_{{MIN\_}2} )}}} & {{{for}\mspace{14mu} X_{{MAX\_}1}} < X < X_{{MIN\_}2}} \\{{f_{2}(X)}} & {{{for}\mspace{14mu} X_{{MIN\_}2}} \leq X \leq X_{{MAX\_}2}}\end{matrix} } & ( {{Equ}.\mspace{14mu} 4} )\end{matrix}$

if X_(MAX) _(—) ₁ is less than X_(MIN) _(—) ₂. And, if X_(MAX) _(—) ₂ isless than X_(MIN) _(—) ₁, the interpolation model may be represented as:

$\begin{matrix}{{f(X)} = \{ \begin{matrix}{{f_{2}(X)}} & {{{for}\mspace{14mu} X_{{MIN\_}2}} \leq X \leq X_{{MAX\_}2}} \\{{{( \frac{{f_{1}( X_{{MIN\_}1} )} - {f_{2}( X_{{MAX\_}2} )}}{X_{{MIN\_}1} - X_{{MAX\_}2}} )( {X - X_{{MIN\_}1}} )} + {f_{1}( X_{{MIN\_}1} )}}} & {{{for}\mspace{14mu} X_{{MAX\_}2}} < X < X_{{MIN\_}1}} \\{{f_{1}(X)}} & {{{for}\mspace{14mu} X_{{MIN\_}1}} \leq X \leq X_{{MAX\_}1}}\end{matrix} } & ( {{Equ}.\mspace{14mu} 5} )\end{matrix}$

As can be seen from equations 1, 4 and 5, the model may comprise aplurality of regression models. In particular, a first regression model(i.e., f₁(X)) may be used to model the dependent variable Y in a firstoperating region (i.e., X_(MIN) _(—) ₁≦X≦X_(MAX) _(—) ₁), and a secondregression model (i.e., f₂(X)) may be used to model the dependentvariable Y in a second operating region (i.e., X_(MIN) _(—) ₂≦X≦X_(MAX)_(—) ₂). Additionally, as can be seen from equations 4 and 5, the modelmay also comprise an interpolation model to model the dependent variableY in between operating regions corresponding to the regression models.

Referring again to FIG. 10, at a block 320, the validity range may beupdated. For example, if X_(MAX) _(—) ₁ is less than X_(MIN) _(—) ₂,then X_(MIN) may be set to X_(MIN) _(—) ₁ and X_(MAX) may be set toX_(MAX) _(—) ₂ Similarly, if X_(MAX) _(—) ₂ is less than X_(MIN) _(—) ₁,then X_(MIN) may be set to X_(MIN) _(—) ₂ and X_(MAX) may be set toX_(MAX) _(—) ₁ FIG. 9C illustrates the new model with the new validityrange.

Referring now to FIGS. 7 and 10, the model may be updated a plurality oftimes using a method such as the method 276. For example, FIG. 11Aillustrates a first group 354 of data sets and a second group 358 ofdata sets outside of the validity region corresponding to the modelillustrated in FIG. 9C, and FIG. 11B illustrates corresponding toregression models generated for the first group 354 of data sets and thesecond group 358 of data sets. Additionally, FIG. 11C illustrates a newupdated model that includes the regression models generated for thefirst group 354 of data sets and the second group 358 of data sets aswell as new interpolation models. Further, 11C illustrates a newvalidity range for the model.

The abnormal situation prevention system 35 (FIGS. 1 and 2) may cause,for example, graphs similar to some or all of the graphs illustrated inFIGS. 6A, 6B, 6C, 8A, 8B, 9A, 9B, 9C, 11A, 11B and 11C to be displayedon a display device. For instance, if the AOD system 100 provides modelcriteria data to the abnormal situation prevention system 35 or adatabase, for example, the abnormal situation prevention system 35 mayuse this data to generate a display illustrating how the model 112 ismodeling the dependent variable Y as a function of the independentvariable X. For example, the display may include a graph similar to oneor more of the graphs of FIGS. 6C, 9C and 11C. Optionally, the AODsystem 100 may also provide the abnormal situation prevention system 35or a database, for example, with some or all of the data sets used togenerate the model 112. In this case, the abnormal situation preventionsystem 35 may use this data to generate a display having a graph similarto one or more of the graphs of FIGS. 6A, 6B, 9A, 9B, 11A and 11B.Optionally, the AOD system 100 may also provide the abnormal situationprevention system 35 or a database, for example, with some or all of thedata sets that the AOD system 100 is evaluating during its monitoringphase. Additionally, the AOD system 100 may also provide the abnormalsituation prevention system 35 or a database, for example, with thecomparison data for some or all of the data sets. In this case, as justone example, the abnormal situation prevention system 35 may use thisdata to generate a display having a graph similar to one or more of thegraphs of FIGS. 8A and 8B.

FIG. 12 is a block diagram of another example AOD system 400 that couldbe used for the abnormal operation detection blocks 80 and 82 of FIG. 2.The AOD system 400 includes a first SPM block 404 and a second SPM block408. The SPM block 404 receives a load variable associated with aprocess and generates a mean signal corresponding to the load variable.Similarly, the SPM block 408 receives a monitored variable associatedwith the process and generates a mean signal based on the monitoredvariable. Additionally, the SPM block 408 generates a standard deviationsignal based on the monitored variable. The mean signals from the SPMblock 404 and the SPM block 408, as well as the standard deviationsignal from the SPM block 408 may be generated using a variety oftechniques, including known techniques. For example, the SPM block 404could generate mean values by calculating the means of non-overlappingblocks of load variable samples. The blocks could have a fixed lengthsuch as a particular number of samples or a time period. As a particularexample used for illustrative purposes, if the block was five minutes inlength, the SPM block 404 would generate a mean value every fiveminutes. The configuration application 38, for example, could be used toconfigure the SPM blocks 404 and 408. Optionally, the SPM blocks 404 and408 may not be readily configurable by an operator.

The mean output of the SPM block 404 is provided as an independentvariable (X) input of a model 412, and the mean output of the SPM block408 is provided as a dependent variable (Y) input of the model 412. Themodel 412 may comprise a model such as the model 112 of FIG. 3, forexample. The mean output of the SPM block 404 is also provided as anindependent variable (X) input of a model 416, and the standarddeviation output of the SPM block 408 is provided as a dependentvariable (Y) input of the model 416. The model 416 may comprise a modelsuch as the model 112 of FIG. 3, for example.

In the AOD system 400, the model 412 generally models the mean of themonitored variable as a function of the mean of the load variable. Themodel 416 generally models the standard deviation of the monitoredvariable as a function of the mean of the load variable. This may beuseful in situations where the standard deviation of the monitoredvariable tends to change as the load variable changes.

The Y_(P) outputs of the models 412 and 416 are provided to a deviationdetector 420. Additionally, the mean output of the SPM block 408 isprovided to the deviation detector 420. The deviation detector 420generally compares the mean (μ_(mv)) of the monitored variable to thepredicted mean (μ_(Pmv)) generated by the model 412. Additionally, thedeviation detector 420 utilizes this comparison as well as the predictedstandard deviation (σ_(Pmv)) generated by the model 416 to determine ifa significant deviation has occurred. More specifically, the deviationdetector 420 generates a status signal as follows:

-   -   if μ_(mv)>μ_(Pmv)+mσ_(Pmv)), then generate the status signal        indicating that the mean μ_(mv) appears to be too high (“UP”);    -   if μ_(mv)<μ_(Pmv)−mσ_(Pmv)), then generate the status signal        indicating that the mean μ_(mv) appears to be too low (“DOWN”);    -   otherwise, generate the status signal indicating that the mean        μ_(mv) appears to be in a normal range (“NO CHANGE”).        where m is a real number that may be fixed or may be modifiable        by a user. As a default, m could be set to 3, for example. Of        course, any other suitable default value could be used. The        value of m could be configured using the configuration        application 38, for example. In some implementations, the status        signal may be in the form of an alert or alarm.

In one particular implementation, the AOD system 400 could beimplemented as a function block, such as a function block to be used insystem that implements a Fieldbus protocol. In another implementation,each of some or all of blocks 404, 408, 412, 416 and 420 may beimplemented as a separate function block.

Using AOD System in a Level Regulatory Control Loop

AOD systems such as those described above can be used in various ways ina process plant to facilitate abnormal situation prevention. An exampleof using AOD systems to prevent an abnormal situation in a process plantwill be described with reference to FIGS. 13 and 14. FIG. 13 is a blockdiagram of an example control system 450 for regulating the level ofmaterial in a tank 454. A control system such as the control system 450is often referred to in the process control industry as a LevelRegulatory Control Loop. The control system 450 includes a flow sensor458 to sense the flow of material into the tank 454, and a flow sensor462 to sense the flow of material exiting the tank 454. The flow sensor458 may generate a signal IF indicative of the flow rate of materialentering the tank 454, for example, and the flow sensor 462 may generatea signal OF indicative of the flow rate of material exiting the tank454, for example. The control system 450 may also include a level sensor466 to sense the level of material in the tank 454. The level sensor 466may generate a signal LVL indicative of the level of material in thetank 454, for example.

A pump 470 may facilitate draining material from the tank 454, and avalve 474 may be used to regulate the flow rate of material exiting thetank. A position of the valve may be altered using a control demand (CD)signal in a manner well known to those of ordinary skill in the art. Thevalve 474 may include a sensor that generates a signal VP indicative ofthe position of the valve.

A PID control routine 478 may be used to control the valve 474 in orderto regulate the level of material in the tank 454 according to a setpoint (SP). Any of a variety of suitable control routines may beutilized for the PID control routine 478. In general, such a routine mayutilize one or more of the following signals to generate a controldemand (CD) signal to appropriately control the valve 454: SP, LVL, VP,IF and/or OF.

In control systems such as the control system 450, two typical abnormalconditions are encountered: a measurement drift and a valve problem. Themeasurement drift condition may be indicative of a problem with asensor, such as the level sensor 466. For example, a measurement driftcondition may result in the signal LVL not accurately indicating theactual level in the tank 454. The valve problem condition may indicate aproblem with the valve 474. This may result, for example, in the VPsignal indicating a different valve position than that indicated by theCD signal. With prior art techniques, such underlying problems may causeanother problem to occur, such as the level in the tank becoming toohigh or too low. This may lead to an alert or alarm being generated. Butit may take an operator some time to determine the underlying problemthat led to the alert/alarm.

FIG. 14 is a block diagram of an example system 500 that may be used todetect an abnormal condition associated with the control system 450 ofFIG. 13. It is to be understood, however, that the system 500 could beused with other control systems as well. It is believed that a systemsuch as the system 500 may help to detect a measurement drift or valveproblem before such underlying conditions lead to a more serious problemsuch as a tank level being too high or too low. Thus, the system 500 mayhelp to limit down time because, for example, replacement parts could beordered in advance of a shut down. Similarly, economic loss may bereduced because a shut down could be scheduled in advance, as opposed tothe system being shut down immediately in response to tank level alarm.Alternatively, a faulty sensor or valve could be replaced withoutshutting the process down.

The system 500 includes a first AOD block 504 and a second AOD block508. Each of the AOD blocks 504 and 508 may comprise an AOD system suchas the AOD system 400 of FIG. 12. Thus, each of the AOD blocks 504 and508 may include a load variable (LV) input, a monitored variable (MV)input, and a status (S) output as in the AOD system 400 of FIG. 12.

Referring now to FIGS. 13 and 14, the LVL signal may be provided to theLV input of the AOD block 504 and also to the LV input of the AOD block508. The CD signal may be provided to the MV input of the AOD block 504.The CD signal may also be provided to a subtraction block 512, alongwith the VP signal. The subtraction block 512 may generate an outputsignal VP-CD, which may be provided to the MV input of the AOD block508. In the system 500, the AOD block 504 generally models the mean ofthe CD signal as a function of the mean of the LVL signal. Similarly,the AOD block 508 generally models the mean of the signal VP-CD as afunction of the mean of the LVL signal.

A status signal S1 generated by the AOD block 504 and a status signal S2generated by the AOD block 508 may be provided to a logic block 516. Thesignals S1 and S2 may be generated in the manner described with respectto FIG. 12. The logic block 516 may generate a control system statussignal that generally indicates whether an abnormal condition has beendetected and provides information as to the type of abnormal condition.For example, the logic block 516 may generate an indicator of a valveproblem if the status signal S2 has a value of either “UP” or “DOWN”.Also, the logic block 516 may generate an indicator of a measurementdrift problem if the status signal S2 has a value of “NO CHANGE” and thestatus signal S1 has a value of either “UP” or “DOWN”. If the statussignals S1 and S2 both have values of “NO CHANGE,” the logic block 516may generate an indicator that no abnormal condition has been detected.

One of ordinary skill in the art will recognize that a system similar tothe system 500 of FIG. 14 could be utilized to detect other types ofabnormal conditions associated with a control system such as the controlsystem 450 of FIG. 13. For example, a similar system could be used todetect a liquid leak condition, a head loss condition, etc.

In one particular implementation, the system 500 could be a functionblock, such as a function block to be used in system that implements aFieldbus protocol. In another implementation, each of at least some ofthe blocks 504, 508, 512, and 516 may be implemented as a functionblock.

Manual Control of AOD System

In the AOD systems described with respect to FIGS. 5, 7 and 10, themodel may automatically update itself when enough data sets have beenobtained in a particular operating region. However, it may be desiredthat such updates do not occur unless a human operator permits it.Additionally, it may be desired to allow a human operator to cause themodel to update even when received data sets are in the validity region.

FIG. 15 is an example state transition diagram 550 corresponding to analternative operation of an AOD system such as the AOD system 100 ofFIG. 3 and AOD system 400 of FIG. 12. The operation corresponding to thestate diagram 550 allows a human operator more control over the AODsystem. For example, as will be described in more detail below, anoperator may cause a LEARN command to be sent to the AOD system when theoperator desires that the model of the AOD system be forced into aLEARNING state 554. Generally speaking, in the LEARNING state 554, whichwill be described in more detail below, the AOD system obtains data setsfor generating a regression model. Similarly, when the operator desiresthat the AOD system create a regression model and begin monitoringincoming data sets, the operator may cause a MONITOR command to be sentto the AOD system. Generally speaking, in response to the MONITORcommand, the AOD system may transition to a MONITORING state 558.

An initial state of the AOD system may be an UNTRAINED state 560, forexample. The AOD system may transition from the UNTRAINED state 560 tothe LEARNING state 554 when a LEARN command is received. If a MONITORcommand is received, the AOD system may remain in the UNTRAINED state560. Optionally, an indication may be displayed on a display device tonotify the operator that the AOD system has not yet been trained.

In an OUT OF RANGE state 562, each received data set may be analyzed todetermine if it is in the validity range. If the received data set isnot in the validity range, the AOD system may remain in the OUT OF RANGEstate 562. If, however, a received data set is within the validityrange, the AOD system may transition to the MONITORING state 558.Additionally, if a LEARN command is received, the AOD system maytransition to the LEARNING state 554.

In the LEARNING state 554, the AOD system may collect data sets so thata regression model may be generated in one or more operating regionscorresponding to the collected data sets. Additionally, the AOD systemoptionally may check to see if a maximum number of data sets has beenreceived. The maximum number may be governed by storage available to theAOD system, for example. Thus, if the maximum number of data sets hasbeen received, this may indicate that the AOD system is, or is in dangerof, running low on available memory for storing data sets, for example.In general, if it is determined that the maximum number of data sets hasbeen received, or if a MONITOR command is received, the model of the AODsystem may be updated and the AOD system may transition to theMONITORING state 558.

FIG. 16 is a flow diagram of an example method 600 of operation in theLEARNING state 554. At a block 604, it may be determined if a MONITORcommand was received. If a MONITOR command was received, the flow mayproceed to a block 608. At the block 608, it may be determined if aminimum number of data sets has been collected in order to generate aregression model. If the minimum number of data sets has not beencollected, the AOD system may remain in the LEARNING state 554.Optionally, an indication may be displayed on a display device to notifythe operator that the AOD system is still in the LEARNING state becausethe minimum number of data sets has not yet been collected.

If, on the other hand, the minimum number of data sets has beencollected, the flow may proceed to a block 612. At the block 612, themodel of the AOD system may be updated as will be described in moredetail with reference to FIG. 17. Next, at a block 616, the AOD systemmay transition to the MONITORING state 558.

If, at the block 604 it has been determined that a MONITOR command wasnot received, the flow may proceed to a block 620, at which a new dataset may be received. Next, at a block 624, the received data set may beadded to an appropriate training group. An appropriate training groupmay be determined based on the X value of the data set, for instance. Asan illustrative example, if the X value is less than X_(MIN) of themodel's validity range, the data set could be added to a first traininggroup. And, if the X value is greater than X_(MAX) of the model'svalidity range, the data set could be added to a second training group.

At a block 628, it may be determined if a maximum number of data setshas been received. If the maximum number has been received, the flow mayproceed to the block 612, and the AOD system will eventually transitionto the MONITORING state 558 as described above. On the other hand, ifthe maximum number has not been received, the AOD system will remain inthe LEARNING state 554. One of ordinary skill in the art will recognizethat the method 600 can be modified in various ways. As just oneexample, if it is determined that the maximum number of data sets hasbeen received at the block 628, the AOD system could merely stop addingdata sets to a training group. Additionally or alternatively, the AODsystem could cause a user to be prompted to give authorization to updatethe model. In this implementation, the model would not be updated, evenif the maximum number of data sets had been obtained, unless a userauthorized the update.

FIG. 17 is a flow diagram of an example method 650 that may be used toimplement the block 612 of FIG. 16. At a block 654, a range [X′_(MIN),X′_(MAX)] may be determined for the regression model to be generatedusing the newly collected data sets. The range [X′_(MIN), X′_(MAX)] maybe implemented using a variety of techniques, including knowntechniques. At a block 658, the regression model corresponding to therange [X′_(MIN), X′_(MAX)] may be generated using some or all of thedata sets collected and added to the training group as described withreference to FIG. 16. The regression model may be generated using avariety of techniques, including known techniques.

At a block 662, it may be determined if this is the initial training ofthe model. As just one example, it may be determined if the validityrange [X_(MIN), X_(MAX)] is some predetermined range that indicates thatthe model has not yet been trained. If it is the initial training of themodel, the flow may proceed to a block 665, at which the validity range[X_(MIN), X_(MAX)] will be set to the range determined at the block 654.

If at the block 662 it is determined that this is not the initialtraining of the model, the flow may proceed to a block 670. At the block670, it may be determined whether the range [X′_(MIN), X′_(MAX)]overlaps with the validity range [X_(MIN), X_(MAX)]. If there isoverlap, the flow may proceed to a block 674, at which the ranges of oneor more other regression models or interpolation models may be updatedin light of the overlap. Optionally, if a range of one of the otherregression models or interpolation models is completely within the range[X′_(MIN), X′_(MAX)], the other regression model or interpolation modelmay be discarded. This may help to conserve memory resources, forexample. At a block 678, the validity range may be updated, if needed.For example, if X′_(MIN) is less than X_(MIN) of the validity range,X_(MIN) of the validity range may be set to the X′_(MIN).

If at the block 670 it is determined whether the range [X′_(MIN),X′_(MAX)] does not overlap with the validity range [X_(MIN), X_(MAX)],the flow may proceed to a block 682. At the block 682, an interpolationmodel may be generated, if needed. At the block 686, the validity rangemay be updated. The blocks 682 and 686 may be implemented in a mannersimilar to that described with respect to blocks 316 and 320 of FIG. 10.

One of ordinary skill in the art will recognize that the method 650 canbe modified in various ways. As just one example, if it is determinedthat the range [X′_(MIN), X′_(MAX)] overlaps with the validity range[X_(MIN), X_(MAX)], one or more of the range [X′_(MIN), X′_(MAX)] andthe operating ranges for the other regression models and interpolationmodels could be modified so that none of these ranges overlap.

FIG. 18 is a flow diagram of an example method 700 of operation in theMONITORING state 558. At a block 704, it may be determined if a LEARNcommand was received. If a LEARN command was received, the flow mayproceed to a block 708. At the block 708, the AOD system may transitionto the LEARNING state 554. If a LEARN command was not received, the flowmay proceed to a block 712.

At the block 712, a data set (X,Y) may be received as describedpreviously. Then, at a block 716, it may be determined whether thereceived data set (X,Y) is within the validity range [X_(MIN), X_(MAX)].If the data set is outside of the validity range [X_(MIN), X_(MAX)], theflow may proceed to a block 720, at which the AOD system may transitionto the OUT OF RANGE state 562. But if it is determined at the block 716that the data set is within the validity range [X_(MIN), X_(MAX)], theflow may proceed to blocks 724, 728 and 732. The blocks 724, 728 and 732may be implemented similarly to the blocks 158, 162 and 166,respectively, as described with reference to FIG. 4.

To help further explain state transition diagram 550 of FIG. 15, theflow diagram 600 of FIG. 16, the flow diagram 650 of FIG. 17, and theflow diagram 700 of FIG. 18, reference is now made to FIGS. 19A-19I,which are graphs to help illustrate an example of how an AOD systemcould operate. FIG. 19A shows a graph 800 illustrating the AOD system inthe LEARNING state 554 while its model is being initially trained. Inparticular, the graph 800 of FIG. 19A includes a group 804 of data setsthat have been collected. After an operator has caused a MONITOR commandto be issued, or if a maximum number of data sets has been collected, aregression model corresponding to the group 804 of data sets may begenerated. The graph 800 of FIG. 19B includes a curve 808 indicative ofthe regression model corresponding to the group 804 of data sets. Then,the AOD system may transition to the MONITORING state 558.

The graph 800 of FIG. 19C illustrates operation of the AOD system in theMONITORING state 558. In particular, the AOD system receives a data set812 that is within the validity range. The model generates a predictionY_(P)(indicated by an x in the graph of FIG. 19C) using the regressionmodel indicated by the curve 808. In FIG. 19D, the AOD system receives adata set 816 that is not within the validity range. This may cause theAOD system to transition to the OUT OF RANGE state 562.

If the operator subsequently causes a LEARN command to be issued, theAOD system will transition again to the LEARNING state 554. The graph800 of FIG. 19E illustrates operation of the AOD system after it hastransitioned back to the LEARNING state 554. In particular, the graph ofFIG. 19E includes a group 820 of data sets that have been collected.After an operator has caused a MONITOR command to be issued, or if amaximum number of data sets has been collected, a regression modelcorresponding to the group 820 of data sets may be generated. The graph800 of FIG. 19F includes a curve 824 indicative of the regression modelcorresponding to the group 820 of data sets. Next, an interpolationmodel may be generated for the operating region between the curves 808and 824.

Then, the AOD system may transition back to the MONITORING state 558.The graph of FIG. 19G illustrates the AOD system again operating in theMONITORING state 558. In particular, the AOD system receives a data set828 that is within the validity range. The model generates a predictionY_(P)(indicated by an x in the graph of FIG. 19G) using the regressionmodel indicated by the curve 824 of FIG. 19F.

If the operator again causes a LEARN command to be issued, the AODsystem will again transition to the LEARNING state 554. The graph 800 ofFIG. 19H illustrates operation of the AOD system after it has againtransitioned to the LEARNING state 554. In particular, the graph of FIG.19H includes a group 832 of data sets that have been collected. After anoperator has caused a MONITOR command to be issued, or if a maximumnumber of data sets has been collected, a regression model correspondingto the group 832 of data sets may be generated. The graph 800 of FIG.19I includes a curve 836 indicative of the regression modelcorresponding to the group 832 of data sets.

Next, ranges of the other regression models may be updated. For example,referring to FIGS. 19F and 19I, the ranges of the regression modelscorresponding to the curves 808 and 824 have been shortened as a resultof adding the regression model corresponding to the curve 836.Additionally, the interpolation model for the operating region betweenthe regression models corresponding to the curves 808 and 824 has beenoverridden by the regression model corresponding to curve 836. Thus, theinterpolation model may be deleted from a memory associated with the AODsystem if desired.

After transitioning to the MONITORING state 558, the AOD system mayoperate as described previously. For example, the graph of FIG. 19Ishows a received data set 840 that is within the validity range. Themodel generates a prediction Y_(P)(indicated by an x in the graph ofFIG. 19I) using the regression model indicated by the curve 836.

Examples of Implementing AOD Systems in One or More Process PlantDevices

As described previously, AOD systems such as those described herein, maybe implemented in a variety of devices within a process plant. FIG. 20is a block diagram showing one possible way in which an AOD system maybe implemented in a process plant. In FIG. 20, a Fieldbus system 900includes a flow transmitter 904 and a temperature transmitter 908 on asame Fieldbus segment 912. The flow transmitter 904 may implement ananalog input function block 914 and an SPM block 916. Additionally, theflow transmitter 904 may implement an abnormal operation detectionfunction block 918. The function block 918 may include at least onemodel and a deviation detector that function in a manner similar to thatdescribed above with respect to FIGS. 3 and/or 12, for example. Thetemperature transmitter 908 may implement an analog input function block922 and an SPM block 924.

In operation, the analog input function block 914 may provide a processvariable signal to the SPM block 916. In turn, the SPM block 916 maygenerate one or more statistical signals based on the process variablesignal, and may provide the statistical signals to the abnormaloperation detection function block 918. Similarly, the analog inputfunction block 922 may provide a process variable signal to the SPMblock 924. In turn, the SPM block 924 may generate one or morestatistical signals based on the process variable signal, and mayprovide the statistical signals to the abnormal operation detectionfunction block 918 via the Fieldbus segment 912.

In another implementation, the SPM blocks 916 and 924 may beincorporated within the abnormal operation detection function block 918.In this implementation, the analog input function block 914 may provideits process variable signal to the abnormal operation detection functionblock 918. Similarly, the analog input function block 922 may provideits process variable signal to the abnormal operation detection functionblock 918 via the Fieldbus segment 912. Of course, as described above,SPM blocks may not always be utilized in connection with abnormaloperation detection function block 918, and thus may be omitted in someimplementations.

As is known, some field devices are capable of making sensing of two ormore process variables. Such a field device may be capable ofimplementing all of blocks 914, 916, 918, 922, and 924.

FIG. 21 illustrates another manner of implementing AOD systems in aprocess plant. In the system 940 of FIG. 21, some or all of the abnormalsituation prevention application 35, the configuration application 38,and/or the alert/alarm application 43 may be stored in a device otherthan a host workstation or personal computer. The example system 940 ofFIG. 21 includes a set of field devices 945 (illustrated as Fieldbusfield devices, but they could be other types of devices as well)connected to an interface device 950, which may be, for example, theRosemount 3420 device. In this case, the interface device 950, which isnot a personal computer, may include some or all of the functionality ofthe abnormal situation prevention system 35 described above. Inparticular, the interface device 950 may include a server application952 to receive and organize data delivered from the field devices 945(which may be various different types of field devices). If desired,this server application 952 may include an OPC server. The configurationapplication 38 (or a portion of it) may also be stored in a memory of,and executed on a processor of, the interface device 950 to allowconfiguration of AOD blocks, SPM blocks, detection logic, models, etc.,as described above. Additionally, the interface device 950 may includeone or more SPM blocks 954 therein to collect process variable datadirectly from one or more of the field devices (such as field deviceswhich do not include SPM blocks or functionality) and to generate SPMparameters, as discussed above. Further, the interface device 950 mayinclude one or more AOD blocks 956 therein to receive the SPM parametersand/or process variable data from field devices and to generateindicators of deviation, as discussed above. In this manner, the SPMblocks 954 and/or the AOD blocks 956 stored in and executed in theinterface device 950 are able to compensate for the lack of SPM blocksand/or AOD blocks within certain ones of the field devices 945 and maybe used to provide SPM data for field devices which do not themselvessupport SPM blocks or SPM functionality and/or models and deviationdetectors for field devices which do not themselves support AOD blocksor AOD functionality. Also, because the interface device 950 maytypically have more memory and more processing power than a fielddevice, implementing SPM blocks and/or AOD blocks in the interfacedevice 950 may permit more complex AOD analysis to be performed. Forexample, more complex regression and/or interpolation models could beimplemented as compared to regression models or interpolation modelsimplemented in a field device.

The interface device 950 may communicate with other devices such as ahost workstation 958 via a hardwired connection, such as a 2-wire, a3-wire, a 4-wire, etc. connection, to provide SPM data, or datadeveloped therefrom, such as alerts, data plots, etc. to those devicesfor viewing by a user. Additionally, as illustrated in FIG. 21, theinterface device 950 may be connected via one or more wirelesscommunication connections to a web browser 960 and to a handheldcomputing device 962, such as a telephone, a personal data assistant(PDA), a laptop computer, etc. In this example, an application may bestored in and executed in other devices, such as the host workstation958, in the web browser 960 or in the handheld computing device 962 andthese applications may communicate with the interface device 950 toobtain data for the application. If desired, the devices 958, 960 and962 may include the configuration application 38 to enable a user toconfigure AOD blocks and/or SPM blocks implemented in the interfacedevice 950. Likewise, as illustrated in FIG. 21, the data from theinterface device 950 may be accessed indirectly from the host 958 by aweb browser 964 and provided to other users via any desired webconnection. Of course, the interface device 950 may include a web servertherein and may communicate with any other device, such as the devices958, 960, 962, and 964 using any desired protocol, such as OPC, Modbus,Ethernet, HTML, XML, etc.

FIG. 22 illustrates a further process plant system 970 in which aninterface device 950, which may be similar to or the same as that ofFIG. 21, is connected between a set of field devices 974 (forming partof a heat exchanger 978) and a process controller system 980. Here, theinterface device 950, which may include all of the applications andfunctionality of the device 950 of FIG. 21, may provide data for viewingto a host 984, and may provide alerts or alarms generated by AOD systemsor other systems to the controller system 980. The controller system 980may integrate these alerts or alarms with other controller type alertsand alarms for viewing by, for example, a control operator at anoperator workstation 988. Of course, if desired, the host workstation984 may include any desired viewing application to view the datacollected in and provided by the interface device 950 in any desiredmanner, including any of those discussed herein. Likewise, this data maybe made available for viewing by other users via a web browser 990.Thus, as will be understood, the various applications discussed hereinas being associated with the abnormal situation prevention system 35,the SPM blocks (if used), and the AOD systems may be distributed indifferent devices. For instance, data (such as SPM data) may becollected in one device, such as a field device 974, and sent to anotherdevice, such as in the interface device 950, that implements an AODsystem. Alerts, alarms, or other indicators generated by the AOD systemmay be sent to yet another device, such as the workstation 988, forpresentation to a user. Likewise, configuration information may be inputvia a user interface device, such as a host, a web browser, a PDA, etc.and sent to a different device, such as the interface device 950, forconfiguring an AOD system.

Reducing Number of Regression Models

As described previously, AOD systems such as those described herein, maybe implemented in a variety of devices within a process plant. In atleast some of these devices, memory resources may be constrained. Withthe AOD systems described above, the model that models the process mayinclude several regression models, and the number of regression modelsmay increase as the process moves into different operating regions, forexample. Additionally, as the number of regression models increases, theamount of memory needed to store parameters (e.g., coefficients) of theregression models may increase. For example, if each regression model isof the form Y=a*X²+b*X+c, then each regression model requires storagefor its respective parameters a, b, and c. Continuing with this example,if there are 10 regression models, the model would require storage for30 parameters. If memory resources of the device implementing the modelare constrained, the increasing number of regression models may use upall available memory. With such devices, it may be useful to limit thenumber of regression models that a model may include and/or to permitreduction in the number of regression models of the model. Hereinafter,a model that includes multiple regression models will be referred to asa composite model for ease of explanation.

To reduce the number of regression models in a composite model, aplurality of adjacent regression models may be merged into a singleregression model. FIG. 23 is a graph illustrating the merger of twoadjacent regression models a(x) and b(x) into a single regression modelα(x). The regression model a(x) may be valid in a region x>a_(min) andx<a_(max), while the regression model b(x) may be valid in a regionx>b_(min) and x<b_(max). There may be an interpolated model (not shown)between a_(max) and b_(min). The regression model α(x) may be chosensuch that it is a model that is a best fit of the regression model a(x)over the region x>a_(min) and x<a_(max) and the regression model b(x)over the region x>b_(min) and x<b_(max) according to some criteria. Forexample, the regression model α(x) could be determined as a model thatprovides the minimum integral square error (ISE) when compared to theregression model a(x) over the region x>a_(min) and x<a_(max) and theregression model b(x) over the region x>b_(min) and x<b_(max).

If the regression models α(x), a(x), and b(x) are polynomials of order psuch that

α(x)=α₀+α₁ x+αx ²+ . . . +α_(p) x ^(p)  (Equ. 6)

a(x)=a ₀ +a ₁ x+a ₂ x ² + . . . +a _(p) x ^(P)  (Equ. 7)

b(x)=b ₀ +b ₁ x+b ₂ x ² + . . . +b _(p) x ^(p),  (Equ. 8)

the ISE between a polynomial α(x) and a polynomial a(x) over the regionx>a_(min) and x<a_(max) and a polynomial b(x) over the region x>b_(min)and x<b_(max) may be written as:

$\begin{matrix}{{{ISE} = {{( {\overset{->}{\alpha} - \overset{->}{a}} )^{T} \cdot A \cdot ( {\overset{->}{\alpha} - \overset{->}{a}} )} + {( {\overset{->}{\alpha} - \overset{->}{b}} )^{T} \cdot B \cdot ( {\overset{->}{\alpha} - \overset{->}{b}} )}}}{{where}\text{:}}} & ( {{Equ}.\mspace{14mu} 9} ) \\{\overset{->}{\alpha} \equiv \lbrack {\alpha_{0}\mspace{20mu} \alpha_{1}\mspace{20mu} \ldots \mspace{20mu} \alpha_{p}} \rbrack^{T}} & ( {{Equ}.\mspace{14mu} 10} ) \\{\overset{->}{a} \equiv \lbrack {a_{0}\mspace{20mu} a_{1}\mspace{20mu} \ldots \mspace{20mu} a_{p}} \rbrack^{T}} & ( {{Equ}.\mspace{14mu} 11} ) \\{A = \begin{bmatrix}A_{1} & A_{2} & \cdots & A_{p + 1} \\A_{2} & A_{3} & \cdots & A_{p + 2} \\\cdots & \cdots & \cdots & \cdots \\A_{p + 1} & A_{p + 2} & \cdots & A_{{2p} + 1}\end{bmatrix}} & ( {{Equ}.\mspace{14mu} 12} ) \\{A_{k} \equiv \frac{a_{\max}^{k} - a_{\min}^{k}}{k}} & ( {{Equ}.\mspace{14mu} 13} ) \\{\overset{->}{b} \equiv \lbrack {b_{0}\mspace{20mu} b_{1}\mspace{20mu} \ldots \mspace{20mu} b_{p}} \rbrack^{T}} & ( {{Equ}.\mspace{14mu} 14} ) \\{B = \begin{bmatrix}B_{1} & B_{2} & \cdots & B_{p + 1} \\B_{2} & B_{3} & \cdots & B_{p + 2} \\\cdots & \cdots & \cdots & \cdots \\B_{p + 1} & B_{p + 2} & \cdots & B_{{2p} + 1}\end{bmatrix}} & ( {{Equ}.\mspace{14mu} 15} ) \\{B_{k} \equiv \frac{b_{\max}^{k} - b_{\min}^{k}}{k}} & ( {{Equ}.\mspace{14mu} 16} )\end{matrix}$

The gradient of the ISE may be written as:

∇ISE=2·A·({right arrow over (α)}−{right arrow over (a)})+2·B·({rightarrow over (α)}−{right arrow over (b)})  (Equ. 17)

The polynomial α(x) that minimizes the ISE can be found by setting thegradient of ISE to zero and solving for {right arrow over (α)}:

{right arrow over (α)}=(A+B)⁻¹(A{right arrow over (a)}+B{right arrowover (b)})  (Equ. 15)

Equation 9 can be extended for the ISE between the polynomial α(x) andthree or more other polynomials:

ISE=({right arrow over (α)}−{right arrow over (a)})^(T) ·A·({right arrowover (α)}− {right arrow over (a)})+({right arrow over (α)}−{right arrowover (b)})^(T) ·B·({right arrow over (α)}− {right arrow over(b)})+({right arrow over (α)}−{right arrow over (c)})^(T) ·C·({rightarrow over (α)}− {right arrow over (c)})+  (Equ. 18)

where {right arrow over (c)} is a vector of the coefficients of a thirdpolynomial c(x) and C is defined similar to A and B above (see Equations12, 13, 15, and 16), etc. Similarly, Equation 18 can be extended tocalculate the polynomial α(x) that minimizes ISE with regard to three ormore other polynomials:

{right arrow over (α)}=(A+B+C+ . . . )⁻¹(A{right arrow over (α)}+B{rightarrow over (b)}+C{right arrow over (c)}+ . . . )  (Equ. 19)

By replacing two or more regression models with a single regressionmodel α(x), the number of parameters that need to be stored can bereduced. For example, if each regression model is of the formY=a*X²+b*X+c, then each regression model requires storage for itsrespective parameters a, b, and c. Continuing with this example, ifthere are 10 regression models, the composite model would requirestorage for 30 parameters. If two of these regression models can becombined into one model, the composite model would then require storagefor only 27 parameters.

FIG. 24 is a flow diagram of an example method 1000 that may beimplemented by an AOD system, such as the AOD system 100 of FIG. 3, theAOD system 400 of FIG. 12, and the AOD block 504 and the AOD block 508of FIG. 14, or some other AOD system. At a block 1004, groups of datasets may be received. Each group may correspond to a different operatingregion of the process, for example. Receiving groups of data sets may beaccomplished in a manner similar to that described above with respect toFIG. 7 or FIG. 16, for example.

At a block 1008, a respective regression model may be generated for eachgroup received at the block 1004. Generating the regression models maybe accomplished in a manner similar to that described above with respectto FIGS. 5, 10, or 17, for example. At a block 1012, a composite modelmay be generated having the regression models generated at the block1008. Generating the composite model may be accomplished in a mannersimilar to that described above with respect to FIGS. 10 and 17, forexample. For instance, generating the composite model may comprisegenerating interpolation models between regression models and updatingvalidity ranges.

The blocks 1004, 1008, and 1012 may be performed in an iterative manner.For example, a first group of data sets may be received, and then afirst regression model may be generated using the first group of datasets. Next, the composite model may be generated as merely the firstregression model. Then, a second group of data sets may be received, anda second regression model generated using the second group of data sets.Next, the composite model may be updated to include the first regressionmodel and the second regression model. This pattern may continue withthird, fourth, fifth, etc., groups of data sets. Generating theresulting composite model may comprise the various updating stages.

On the other hand, two or more groups of data sets could be receivedbefore any regression models are generated. Similarly, two or moreregression models could be generated before a composite model isgenerated and/or updated.

At a block 1016, a new model may be generated using a plurality of theregression models generated at the block 1008. For example, two or moreregression models may be merged into a single model using a techniquesuch as the technique described above with reference to FIG. 23. At ablock 1020, the composite model may be revised to replace the two ormore regression models with the new model.

The new model may be generated from particular regression modelsaccording to some criteria. For example, the new model may be generatedfrom the first two regression models in some list, or the last tworegression models in the list. As another example, the new model may begenerated from two adjacent regression models having a smallest gapbetween their respective validity ranges. If more than one pair ofregression models have the same smallest gap, other criteria can be usedto select one pair. As yet another example, the new model may begenerated from two adjacent regression models having a smallestcumulative validity range. As yet another example, the new model may begenerated from the two adjacent regression models giving the smallestintegral square error, between the new model and the two adjacentregression models. One of ordinary skill in the art will recognize manyother ways to select two or more regression models that are to bemerged. For instance, a pair of adjacent regression models may be chosenpseudorandomly.

FIG. 25 is a flow diagram of an example method 1040 for updating acomposite model by selecting two or more regression models for merger.At a block 1044, a plurality of new models may be generated, where eachnew model corresponds to a merger of a different subset of regressionmodels. For example, a new model may be generated for each possiblecombination of a particular number of adjacent regression models in thecomposite model.

Then, at a block 1048, one of the new models may be selected accordingto some criteria. For example, the new model that has the lowest ISE maybe selected. In this implementation, the method 1040 may includecalculating the ISE for each new model. The blocks 1044 and 1048 may beimplemented iteratively. For example, as each additional regressionmodel is added to the composite model, one or more new modelscorresponding to the merger of the additional regression model with anyadjacent regression models may be calculated, and the ISE for each ofsuch new model may be calculated and stored for future use.

At a block 1052, the composite model may be revised to replace with thechosen new model the corresponding subset of regression models in amanner similar to that described previously.

To illustrate application of the method 1040, an example will bedescribed. FIG. 26A is a graph of an example composite model includingfour regression models 1060A, 1060B, 1060C, and 1060D, each regressionmodel of the form Y=a₀+a₁*X+a₂*X². Table 1 includes the validity rangesand coefficients of the regression models 1060A, 1060B, 1060C, and1060D.

TABLE 1 Regression Model Xmin Xmax a₀ a₁ a₂ 1060A 6.0129 6.9805 18.3933−5.0544 0.3891 1060B 7.5225 8.4781 20.1076 −4.5600 0.2912 1060C 9.02379.9692 −12.3376 2.7415 −0.1215 1060D 10.5020 11.4418 1.5813 −0.62560.0727Additionally, the composite model includes three interpolation models1062A, 1062B, 1062C, and 1062D.

FIG. 26B illustrates a new model 1064A generated using the regressionmodels 1060A and 1060B. The new model 1064A would replace the regressionmodels 1060A and 1060B as well as the interpolation model 1062A. FIG.26C illustrates a new model 1064B generated using the regression models1060B and 1060C. The new model 1064B would replace the regression models1060B and 1060C as well as the interpolation model 1062B. FIG. 26Dillustrates a new model 1064C generated using the regression models1060C and 1060D. The new model 1064C would replace the regression models1060C and 1060D as well as the interpolation model 1062C. Table 2includes the validity ranges and coefficients of the new models 1064A,1064B, and 1064C, as well as their associated ISE's.

TABLE 2 New Model Xmin Xmax a₀ a₁ a₂ ISE 1064A 6.0129 8.4781 3.1165−0.4425 0.0421 0.003186 1064B 7.5225 9.9692 8.4027 −1.6566 0.11140.000483 1064C 9.0237 11.4418 15.9324 −3.0553 0.1750 0.005270

It can be seen from Table 2 that the new model 1064B has the lowestassociated ISE. Thus, the composite model can be revised to replace theregression models 1060B and 1060C as well as the interpolation model1062B with the new model 1064B. FIG. 26E is an illustration of therevised composite model. Table 3 includes the validity ranges andcoefficients of the models (not including the interpolation models) ofthe revised composite

TABLE 3 Model Xmin Xmax a₀ a₁ a₂ 1060A 6.0129 6.9805 18.3933 −5.05440.3891 1064B 7.5225 9.9692 8.4027 −1.6566 0.1114 1060D 10.5020 11.44181.5813 −0.6256 0.0727

FIG. 27 is a flow diagram of an example method 1070 for updating acomposite model that may have a limit to the number of regression modelsit may include. The method 1070 includes like numbered blocks from themethod 276 of FIG. 10 and can be utilized as an alternative to themethod 276 of FIG. 10. After the blocks 304, 308, 316, and 320 describedabove with reference to FIG. 10 (i.e., after a new regression model hasbeen generated and the composite model has been updated), at a block1074 a number N of regression models in the composite model may beincremented. Then, at a block 1078, it may be determined if the number Nis equal to a number N_(MAX). The number N_(MAX) may be a maximum numberof regression models that the composite model may include.Alternatively, the number N_(MAX) may be a number that is some amountless than the maximum number of regression models that the compositemodel may include. For example the number N_(MAX) may be one, two,three, etc., less than the maximum number of regression models that thecomposite model may include. In other implementations, it may bedetermined if the number N is greater than greater than N_(MAX), or itmay be determined if the number N is greater than or equal to N_(MAX).

If it is determined that the N is not equal to N_(MAX), the flow mayend. If, however, it is determined that the N is equal to N_(MAX), theflow may proceed to a block 1082. At the block 1082, a new model may bedetermined using as subset of the regression models, and the compositemodel may be revised to replace the subset with the new model. Then, ata block 1086, the number N may be decremented. For example, if the newmodel replaces two regression models, the number N may be decremented byone. As another example, if the new model replaces three regressionmodels, the number N may be decremented by two. Optionally, the blocks1082 and 1086 may be repeated one or more times. Similarly, the block1082 could be repeated one or more times, and then, at the block 1086,the number N may be decremented by an appropriate amount.

Additionally, although example methods for reducing the number ofregression models were described in the context of regression modelshaving a single independent variable input X and a single dependentvariable input Y, the methods could also be used with regression modelsthat model multiple variables Y as a function of multiple variables X.For example, a new model could be generated to replace two or more MLRmodels, PCR models, PLS models, RR models, VSS models, SVM models, etc.Similarly, although example methods for reducing the number ofregression models were described in the context of linear regressionmodels that utilize polynomials, it is to be understood that the methodsmay also be implemented with other types of the models such as modelsthat utilize sinusoidal functions, logarithmic functions, exponentialfunctions, power functions, etc.

One of ordinary skill in the art will recognize that the example systemsand methods described above may be modified in various ways. Forexample, blocks may be omitted, reordered, or combined, additionalblocks may be added, etc. As just one specific example, with regard toFIG. 16, the block 604 could be implemented at a different point in theflow. Similarly, the block 604 could be implemented as an interruptroutine, and thus it could actually occur at various points with theflow of FIG. 16 depending upon when the MONITOR command is received.

Although examples were described in which a regression model comprised alinear regression model of a single dependent variable as a function ofa single independent variable, one of ordinary skill in the art willrecognize that other linear regression models and non-linear regressionmodels may be utilized. One of ordinary skill in the art will alsorecognize that the linear or non-linear regression models may modelmultiple dependent variables as functions of multiple independentvariables.

The AOD systems, models, regression models, interpolation models,deviation detectors, logic blocks, method blocks, etc., described hereinmay be implemented using any combination of hardware, firmware, andsoftware. Thus, systems and techniques described herein may beimplemented in a standard multi-purpose processor or using specificallydesigned hardware or firmware as desired. When implemented in software,the software may be stored in any computer readable memory such as on amagnetic disk, a laser disk, or other storage medium, in a RAM or ROM orflash memory of a computer, processor, I/O device, field device,interface device, etc. Likewise, the software may be delivered to a useror a process control system via any known or desired delivery methodincluding, for example, on a computer readable disk or othertransportable computer storage mechanism or via communication media.Communication media typically embodies computer readable instructions,data structures, program modules or other data in a modulated datasignal such as a carrier wave or other transport mechanism. The term“modulated data signal” means a signal that has one or more of itscharacteristics set or changed in such a manner as to encode informationin the signal. By way of example, and not limitation, communicationmedia includes wired media such as a wired network or direct-wiredconnection, and wireless media such as acoustic, radio frequency,infrared and other wireless media. Thus, the software may be deliveredto a user or a process control system via a communication channel suchas a telephone line, the Internet, etc. (which are viewed as being thesame as or interchangeable with providing such software via atransportable storage medium).

Thus, while the present invention has been described with reference tospecific examples, which are intended to be illustrative only and not tobe limiting of the invention, it will be apparent to those of ordinaryskill in the art that changes, additions or deletions may be made to thedisclosed embodiments without departing from the spirit and scope of theinvention.

1. A method for generating a model of a process in a process plant,comprising: collecting a plurality of groups of data sets for theprocess in the process plant, the data sets generated from processvariables of the process; generating a plurality of regression models ofthe process using the groups of data sets, wherein each regression modelis generated using a corresponding group of data sets from the pluralityof groups, and wherein each regression model comprises a plurality ofcorresponding parameters generated using the corresponding group of datasets; generating a composite model of the process to include theplurality of regression models; generating a new model of the processusing parameters of at least two of the regression models; and revisingthe composite model of the process to replace the at least two of theregression models with the new model.
 2. A method according to claim 1,wherein each group of data sets in the plurality of groups of data setscorresponds to a different operating region of the process; wherein eachregression model of the plurality of regression models corresponds to adifferent operating region of the process; wherein the at least tworegression models comprise regression models from adjacent operatingregions.
 3. A method according to claim 2, wherein the at least tworegression models comprises a first regression model and a secondregression model; wherein the method further comprises generating aninterpolated model between the first regression model and the secondregression model in the at least two regression models; wherein revisingthe composite model of the process comprises revising the compositemodel of the process to replace the at least two of the regressionmodels and the interpolated model with the new model.
 4. A methodaccording to claim 1, further comprising choosing the at least tworegression models from the plurality of regression models.
 5. A methodaccording to claim 4, wherein choosing the at least two regressionmodels comprises determining the at least two regression models thatwill result in a new model having a smallest associated error.
 6. Amethod according to claim 1, further comprising: generating a pluralityof new models of the process corresponding to respective groups ofregression models, wherein each new model is generated using parametersof the regression models in the corresponding group of regressionmodels; choosing one of the new models; and wherein revising thecomposite model comprises revising the composite model of the process toreplace with the selected one of the new models the corresponding groupof regression models.
 7. A method according to claim 6, furthercomprising determining for each new model a corresponding indicator ofdifference between the new model and the corresponding group ofregression models; wherein selecting one of the new models comprisesselecting a new model having the smallest corresponding indicator ofdifference.
 8. A method according to claim 7, wherein determining foreach new model the corresponding indicator of difference between the newmodel and the corresponding group of regression models comprisesdetermining a corresponding integral square error between the new modeland the corresponding group of regression models; wherein selecting thenew model having the smallest indicator of difference comprisesselecting the new model having the smallest corresponding integralsquare error.
 9. A tangible medium storing machine readableinstructions, the machine readable instructions capable of causing oneor more machines to: collect a plurality of groups of data sets for theprocess in the process plant, the data sets generated from processvariables of the process; generate a plurality of regression models ofthe process using the groups of data sets, wherein each regression modelis generated using a corresponding group of data sets from the pluralityof groups, and wherein each model comprises a plurality of correspondingparameters generated using the corresponding group of data sets;generate a composite model of the process to include the plurality ofregression models; generate a new model of the process using parametersof at least two of the regression models; and revise the composite modelof the process to replace the at least two of the regression models withthe new model.
 10. A method for generating a model of a process in aprocess plant, comprising: collecting data sets for the process in theprocess plant, the data sets generated from process variables of theprocess; generating a new regression model of the process using thecollected data sets; revising a composite model of the process toinclude the new regression model in a plurality of regression models ofthe composite model; wherein each regression model in the plurality ofregression models comprises a plurality of corresponding parametersgenerated using a corresponding group of data sets from a plurality ofgroups of data sets; determining whether a number N of regression modelsin the composite model exceeds a number N_(MAX); if the number N ofregression models exceeds the number N_(MAX), generating a new model ofthe process using parameters of at least two of the regression models inthe plurality of regression models; and revising the composite model ofthe process to replace the at least two of the regression models withthe new model.
 11. A method according to claim 10, wherein each group ofdata sets in the plurality of groups of data sets corresponds to adifferent operating region of the process; wherein each regression modelof the plurality of regression models corresponds to a differentoperating region of the process; wherein the at least two regressionmodels comprise regression models from adjacent operating regions.
 12. Amethod according to claim 11, wherein the at least two regression modelscomprises a first regression model and a second regression model;wherein the composite model comprises an interpolated modelcorresponding to a region between a first operating region correspondingto the first regression model and a second operating regioncorresponding to the second regression model in the at least tworegression models; wherein revising the composite model to replace theat least two of the regression models with the new model comprisesrevising the composite model to replace the first regression model, thesecond regression model, and the interpolated model with the new model.13. A method according to claim 10, further comprising choosing the atleast two regression models from the plurality of regression models. 14.A method according to claim 13, wherein choosing the at least tworegression models comprises determining a subset of regression modelsfrom a plurality of subsets of regression models that will result in anew model having a smallest associated error.
 15. A method according toclaim 10, further comprising: generating a plurality of new models ofthe process corresponding to respective groups of regression models,wherein each new model is generated using parameters of the regressionmodels in the corresponding group of regression models; selecting one ofthe new models; and wherein revising the composite model of the processto replace the at least two regression models comprises revising thecomposite model of the process to replace with the selected one of thenew models the corresponding group of regression models.
 16. A methodaccording to claim 15, further comprising determining for each new modela corresponding indicator of difference between the new model and thecorresponding group of regression models; wherein selecting one of thenew models comprises selecting a new model having the smallestcorresponding indicator of difference.
 17. A method according to claim16, wherein determining for each new model the corresponding indicatorof difference between the new model and the corresponding group ofregression models comprises determining a corresponding integral squareerror between the new model and the corresponding group of regressionmodels; wherein selecting the new model having the smallest indicator ofdifference comprises selecting the new model having the smallestcorresponding integral square error.
 18. A tangible medium storingmachine readable instructions, the machine readable instructions capableof causing one or more machines to: collect data sets for the process inthe process plant, the data sets generated from process variables of theprocess; generate a new regression model of the process using thecollected data sets; revise a composite model of the process to includethe new regression model in a plurality of regression models of thecomposite model; wherein each regression model in the plurality ofregression models comprises a plurality of corresponding parametersgenerated using a corresponding group of data sets from a plurality ofgroups of data sets; determine whether a number N of regression modelsin the composite model exceeds a number N_(MAX); if the number N ofregression models exceeds the number N_(MAX), generate a new model ofthe process using parameters of at least two of the regression models inthe plurality of regression models; and revise the composite model ofthe process to replace the at least two of the regression models withthe new model.
 19. A system for detecting an abnormal operation in aprocess plant, comprising: a configurable composite model of the processin the process plant comprising a plurality of regression models, eachregression model having been generated using a corresponding group ofdata sets from a plurality of groups of data sets, the data setsgenerated from process variables of the process, wherein each regressionmodel comprises a plurality of corresponding parameters generated usingthe corresponding group of data sets, wherein the configurable compositemodel is capable of being subsequently configured to replace at leasttwo of the regression models with a new model generated using parametersof the at least two of the regression models; and the system furthercomprising a deviation detector coupled to the configurable compositemodel, the deviation detector configured to determine if the processsignificantly deviates from an output of the composite model.
 20. Asystem according to claim 19, wherein the configurable composite modelis capable of being configured to include a further regression model inthe plurality of regression models.
 21. A system according to claim 19,wherein the configurable composite model is capable of replacing withthe new model at least one interpolated model and the at least tworegression models.
 22. A system according to claim 21, wherein theconfigurable composite model is capable of generating a prediction of aY value as a function of an X value, wherein the Y value is generatedfrom a dependent process variable and the X value is generated from anindependent process variable;
 23. A system according to claim 22,wherein the deviation detector is configured to determine if the Y valuesignificantly differs from the predicted Y value.
 24. A system accordingto claim 23, wherein the deviation detector is configured to determineif the Y value significantly differs from the predicted Y value bycomparing a difference between the Y value and the predicted Y value toa threshold.
 25. A system according to claim 24, wherein the thresholdvaries as a function of the X value.
 26. A system according to claim 23,further comprising: a first statistical generator coupled to theconfigurable composite model, the first statistical generator togenerate the X values as a mean of the independent process variable; anda second statistical generator coupled to the configurable compositemodel, the second statistical generator to generate the Y values as amean of the dependent process variable.
 27. A system according to claim26, wherein the second statistical generator additionally generatesstandard deviation values of the dependent process variable; the systemfurther comprising an additional configurable composite model coupled tothe first statistical generator, the second statistical generator, andthe deviation detector, the additional configurable composite model togenerate a prediction of the standard deviation of the dependent processvariable as a function of the mean of the independent process variable;wherein the deviation detector is configured to determine if the Y valuesignificantly differs from the predicted Y value by comparing adifference between the Y value and the predicted Y value to a threshold,wherein the threshold is a function of the prediction of the standarddeviation.